2003 Dodge 5.9 diesel NV5600 knock/tap/clatter, Ideas?

[Tuesdak]

The noise is getting worse and has been present since I bought it.

Rotated the CP3 to sync with the engine first 45 degrees than 30 degrees and maybe this added a tap at idle. #4 line and all other clamps tight. Clutch in/out doesn't make a difference. (Less fuel with clutch in but noise is still there.) Fuel on or off makes a difference and just holding a steady speed is a constant noise.

 

[Prairie Dog]

I can't hear it but have you tried running some Seafoam through it?

 

[S.Morris]

Confused..........so are you saying it makes this same noise sitting still in neutral? Cluth in or out makes not difference? transmission shifts into gear fine from neutral at dead stopped?

 

[Tuesdak]

The metallic clack is not as loud when the clutch is in when the engine is revved up. So out of gear sitting still there is some noise around 2K RPM esp if I snap the throttle open. Having the fuel on, aka on the throttle, makes the noise. As soon as I let off the throttle the noise is gone. It's fairly loud in the cab IMO louder than the CP3 sync knock some have posted. It's like a bad lifter or exhaust leak.

The noise is there on the first video until 6 seconds when I let off the throttle. And then comes back when I get back into the throttle. Pointing the camera mic at the center gear shift makes the noise louder in the video.

Checked the exhaust manifold for leaks and no cracks/leaks. It does have a Pacbrake. Any other common exhaust leak areas?

Running a 2x dose of Powerservice now. I can throw seafoam at it for grins.

Would a valve adjustment make a difference with the noise changing under throttle or not? Supposedly it was done by the prior owner.

 

[xDiesel03]

Before I did my valve adjustment I had a slight tick at idle, but it wasn't noticeable under higher loads or RPMs, and it didn't sound like the noise you are experiencing. What you are experiencing sounds like the tick everyone talks about with their CP3. I would keep reclocking your CP3 30 degrees at a time until you have gone full circle. Couldn't hurt to check you valve lash as well.

 

[MMeier]

Kinda hard to hear in the videos you put up... are you sure it is coming from the engine and not , perhaps say something like the input shaft bearing in the trans ?

 

[ColemanR]

I can't hear it in the vids but I had what I thought was a loose rocker reset everything didnt change a thing and it was worse when cold. Turned out to be the injectors installed BB 1's Im shocked how quite my truck is over the years I've noticed some trucks are alot louder(rattling) then others.

 

[Tuesdak]

Checked the valves and they are all in spec. Must say it was an easy pleasant job to do for a change. I will try re-clocking the CP3 again. Otherwise I am suspecting a noisy injector. It's simply too fuel related to be much else. Other than a careful exhaust leak inspection, but, nothing so far found.

With the vibration in the clutch pedal I have been putting off it very well could be the trans input shaft.

 

[Tuesdak]

The clatter isn't as harsh after another 30 degrees on the CP3. Quite a reduction in noise, but, still there. Do I need to go 15 degrees?

 

[AllianceDiesel]

It sounds like injector knock to me but its kinda hard to diagnose over the internet.

 

[Tuesdak]

Noise has gotten worse/louder and occurs with no fuel now. And loudest around 1700 RPM. Does not do it in the parking lot aka without a load.

Seafoam did not help.

Head on the engine is painted grey indicating it's been off for whatever reason in the past. Vibration in clutch pedal was solved and did not change the noise.

Only thing I can add is sometimes I get a hard hot start with black smoke.

So it's at a local shop that specializes in Dodge Cummins diesel rigs including wild triple turbo setups. They haven't seen this specific noise or problem exactly before. Hopefully they can track it down.

 

[Mathes308]

Does sound like a bad injector solinoid.
Would be worse with more throttle.
Maybe the shop will kill one at s time and see.

 

[Tuesdak]

Oddly they can't kill a cylinder at a time under load - just at idle. Limitation of an aftermarket scanner or the 2003 ECM?

 

[AH64ID]

It is hard to diagnose over the internet but you should NEVER use seafoam on a diesel.

Seafoam contains alcohol and that emulsifies the water to the point it cannot be filtered/separated and it will do damage to your fuel system. Only use non-alcohol cleaners/additives.

 

[Mathes308]

If they have an old solenoid and injector around you could plug it in place to simulate so the ECM thinks things are fine.
I would think with the valve cover off and a load applied one should hear it rapping pretty good, especially with a mechanics stethoscope.

 

[Tuesdak]

I'll have to tell then to put it on the dyno to get it under a load.

 

[Bob4x4]

Cap of the fuel line to the offending cylinder

 

[Tuesdak]

Cap of the fuel line to the offending cylinder

No change. Capped off and still there.

 

[Tuesdak]

Pulled head and there appears to be lots of carbon build up. No the exhaust manifold isn't going back on - it's done.

 

[AH64ID]

How often do you tow?