Back to TDR for help

[1RWeiss]

When researching my purchase of my 03 CTD years ago I used TDR as a great reference tool, now 4 years later I'm back with a strange problem that I'm afraid to even take to the dealer.



After 65k trouble free miles now when towing my 5th wheel (24' 8,000 lbs) I have been getting a noise that sounds like pinging but could be more "mechanical" like bearings. The strange part is, it only occurs at certain RPM's, it seems to happen mostly at 1700 & 2100 RPMS. If I load it down at those rpms the sound gets louder so I have been laying off the throttle passing through those rpm ranges.



Here is a more complete llist of symptoms,



Loudest at 1700 & 2100 rpm.

Only when towing.

If engine cools down symptoms go away, to return when hot.

Running Bully Dog in "Tow" mode, re-loaded same problem, although I have not tried going back to stock.

Always run fuel stabilizer/octane enhancer.

NO POWER LOSS what so ever.

No codes.

No smoke.

Starts on first click of key like day one.



I thought about fueling issue like lift pump (original) but wouldn't that accompany a power loss or stutter?



Thanks



Ron

 

[SierraRam]

Sounds like a injector knock, could be onjector or FCA. When my 03 FCA started to fail the first thing I noticed was injector knock then it progressed to rough idle and eventually stalling at idle.



SR

 

[AllianceDiesel]

yep you have an injector going out, thats the sweet spot for injector knock, what are your idle times?

 

[Southbound]

Ron-



I had the same symptoms but probably not to the degree your experiencing now. After talking with my buddy who works at the Dodge dealership he recommended running a diesel injector cleaner through the tank a couple of times to see if that helps. Note: I am running 2 micron by-pass fuel filter so the issue is not as much with dirty fuel but more to do with crappy fuel. Note: After running the injector cleaner I have noticed night and day differences with the injector knock. You might try this first but I agree with the others that your probably on your way to new injectors if the damage is done. I am currently using the Valvoline Synpower injector cleaner. Good luck... .



Southbound

 

[1RWeiss]

Sure does sound like a fuel issue, a good cleaner is worth a shot.



As far as an FCA goes that might worth investigating. Does anyone know a Cummins dealer that sells on line that would sell me an FCA??? I know a Dodge dealer wants over $300 for one.



Keep the ideas coming.



Ron W.

 

[1RWeiss]

Mopartimes,



What do you mean by idle times?



Ron

 

[jjdiesel]

I would definitely try running it without the programmer... see what happens.

 

[HBarlow]

1RWeiss,



I had the same problem on my 2006 Ram. It had around 210k miles on it at the time. I listened (with skepticism) to all the advice about running snake oil with magical properties in the fuel tank or fuel injector cleaning techniques administered by dealers but remained unconvinced.



I took the truck 300 miles to an honest dealer where I have bought three Dodge Rams where there is a level 4 trained Dodge-Cummins technician and paid him to run the engine diagnostics tests. He found no injector problems.



I purchased a Fuel Control Actuator (FCA) from a Cummins dealer for about $100 and my mechanic friend installed it. The "timing rattle" sound you described disappeared.



It seems to be a common problem with the last series 5. 9 engines.

 

[AllianceDiesel]

well guess what, I am a level 4 dodge/cummins tech, I have replaced over 100 injectors for this same problem and it has fixed it every time, and the funny thing is, I have never replaced a FCA.



Idle times, are anytime you are ideling the truck and not putting a load on the engine. Idleing the common rails is hard on the injectors and engine. What happens is that, the cylinder head is so effective at cooling the cylinders that when you idle the truck and don't have a load on it, the cylinder temps drop and when the temps really drop, the fuel doesn't completly burn. When this happens it produces carbon which can eventually work its way up into the injector and stick the injector open.



The funny thing is, when all these injector problems started everybody thought I was full of ****, but now if you read they are telling you not to idle your trucks more than needed.

 

[JJPage]

Sure does sound like a fuel issue, a good cleaner is worth a shot.



As far as an FCA goes that might worth investigating. Does anyone know a Cummins dealer that sells on line that would sell me an FCA??? I know a Dodge dealer wants over $300 for one.



Keep the ideas coming.



Ron W.

I do not know of a dealer online, but the Cummins part #4932457 will get you a new FCA for $90. 00+ (ETR FUEL CONTROL ACTUATOR).



Try running a quart of ashless 2 cycle oil in your fuel tank (tcw3), this ULSD is hard on pumps and injectors. within 20 miles my injector clatter was to a minimum. If you still have a rattle, then consider pulling injectors.



A little bit of timing rattle does not hurt, check your crankcase level, to be sure you are not pumping fuel into it from a leaky injector. I believe an awful lot of injectors have been changed out for no good reason. You have an 03, the 04. 5+ models had the most injector failures.



Just my . 02, Jess