Engine Bad at 7K/Injector Question??

[Flotho]

Hi All:



The engine in my '06 3500 apparently had the #3 injector go bad while pulling an 8000 lb. load up a grade.



I did not notice anything wrong until I got off the freeway. At the stoplight while waiting, I noticed a slight lope in the engine that came and went. I thought it might be an injector going bad, and SLOWLY moved the truck/trailer toward a safe parking area less than a block away.



As I pulled away from the light, the misfire increased, and then a knocking noise started. I shut the truck off and called a friend to pick up the trailer to continue less than a mile from my original destination. Then I called DC to have the truck towed to the dealer.



While waiting for the tow truck, I disconnected the wiring harness connectors to the injectors (at the valve cover) to prevent the engine from starting. Then I cranked the engine over and noticed it sounded like no compression in one cylinder. This was verified after the mechanic at the dealer found a broken valve had dropped into the cylinder. A new engine is on order for the truck. but I have a question:



Is the injector problem with the HPCR fuel system a contamination (filtration) problem, or one of fuel lubricity?



I do not wish to be out of my new truck for another month (regardless of who pays for it) if this happens again. There aren't any issues with warranty (yet), and the truck has no mods of any kind installed on it. I just don't want to have this happen again. Major repairs on a brand new truck is a sad thing indeed, but at least the mechanic is replacing the whole longblock instead of doing patchwork.



My other concern is that if I add a 2-3 micron fuel filter and/or use Stanadyne PF, LF, etc. that it may ring the warranty bell at DC.



My last question regarding the "warranty death" issues with DC is regarding an exhaust brake. The truck has a manual transmission, and I would like to add an exhaust brake for the grades I descend often. Is there an "approved" engine brake available? I heard that Cummins has one available, but am concerned that DC may not allow its installation since it modifies the exhaust system, which is connected to the engine, which has a DC warranty, which they apparently like, to void, etc.



Any insight into these questions would be greatly appreciated. I have already had the good fortune of having an injector fail under the worst possible conditions, and don't want any more bad juice coming my way.



I am a mechanic by trade, and there were no indicators of the impending failure. The truck ran fine before I got onto the freeway, no smoke (black or white) or misfire while under way for the 20 mile trip, just an intermittent misfire after I got off the freeway at the traffic light. Just 300 feet later; catastrophic engine failure.



The only thing that I could think of that would indicate an impending failure like this would be an EGT gauge with 6 probes (like on an aircraft engine). With this type of gauge, least you could see a spike in the EGT of the offending cylinder and pull over before the valve stem meltdown.



But, DC would probably void my warranty for drilling into the exhaust manifold to install the probes.



Please advise me on the non power enhancing mods I am enquiring about, as I am a little gun shy after this experience.

 

[JLibert]

As far as the exhaust brake, the jacobs or jake brake is a dealer approved part. You may wan't to check the specifics on whether or not they'll still cover you if you install it yourself.

About the 2 micron filter: I'd talk to the manager at your dealership. Show him a printout of the glacier 2mk system and see what he thinks. Anybody with any sense would agree that added filtration would be a good thing, especially given your luck so far. The only consideration would be added strain on the fuel pump, but others on this site have posted that less than 1psi drop was realized after the addition of an auxillary filter.

 

[crabman]

Flotho,

The 06's have the jacobs exhaust brake as an option. If you buy it from the dealer and have it installed it is an aftermarket item and is covered by Morpars 12 months or 12K miles. Some TDR members have reported that they have vacuum pump problems that show up after warranty expires, app. $700 item.

Pacbrake & BD make ones that fit and work as good if not better than Jacobs.

I would think about installing the the 2 micron fuel filter and a fuel/water separator. Try this site.

Preventive Maintenance!

Good Luck!!



crabman

 

[sag2]

If the valve or seat broke it was probably not from the injector. However if something got loose in that cylinder they are probably replacing the injector anyway.

 

[Cummins724]

I'm sorry to hear the bad news, but I'm sure it will be fixed right by cummins. You'll be back on TDR one day with your 500k mile badge hanging in your window praising the engine... . as we all do. What year is the truck? I'd make sure that the dealership gave me a loaner to beat until the truck was done. Atleast you bought a Dodge & not a Ford... . as my friend did. His truck cracked heads twice & 15 other times in the shop for different problems that aren't getting cured. I could out pull his Ford Powerstroke with a old Chevy 350 truck easily [proved that], but ford says that nothing is wrong with it. It has such low power... You shift down to second to go up hills empty. He can't keep up with me going to work when I am pulling hills with 18k on the trailer. I'm tired of pulling over saying "wheres Dave". He is in a lawsuit as we speak trying to get a new engine cause he wouldn't listen. I told him 6. 0 is junk. Cummins would have replaced the engine, but this Ford is why I call them "Powerjokes".

 

[Regcabguy]

Jake warranty.

Flotho,

The 06's have the jacobs exhaust brake as an option. If you buy it from the dealer and have it installed it is an aftermarket item and is covered by Morpars 12 months or 12K miles. Some TDR members have reported that they have vacuum pump problems that show up after warranty expires, app. $700 item.

Pacbrake & BD make ones that fit and work as good if not better than Jacobs.

I would think about installing the the 2 micron fuel filter and a fuel/water separator. Try this site.

Preventive Maintenance!

Good Luck!!



crabman

The exhaust brake is warranteed for 3yr/36,000 miles. I'd have it installed by the dealer so there are no warranty problems. MAVERICK'S is up today!

 

[betterthanstock]

Hi All:



The engine in my '06 3500 apparently had the #3 injector go bad while pulling an 8000 lb. load up a grade.



I did not notice anything wrong until I got off the freeway. At the stoplight while waiting, I noticed a slight lope in the engine that came and went. I thought it might be an injector going bad, and SLOWLY moved the truck/trailer toward a safe parking area less than a block away.

It could have been a stuck injector causing overheat and a dropped valve seat, and then a broken valve, or just a defective/mishandled valve that just broke. Maybe you could find out if it was a dropped seat or not.

 

[Flotho]

The tech is not going to remove the head. I saw the spring, keepers, spring retainer, etc. , but no valve. I will never know about the seat. He did however, test the injectors and said the injector was bad in that cylinder. Chicken, or egg first?

 

[TMoe]

What's causing injector failure?

We need to find out what's causing injector failures. I, like everyone else, eapecially don't want to be on vacation and have a major melt down if preventable. If it is filtration easy fix with 2 micron filter. If it is lubricity what is the answer? Some type of additive. The TDR magazine had some recommendations. Bosch should know all about this with all the Duramax injector failures. Problem gets even more complex with new ULSD fuel, another variable. In the end we may have an injector replacement interval. Not bad if the price drops drastically. I believe GM went to 2 micron filtration that may have helped. That's where I'm going. I don't see how lowering flow a little for stock applications with additional filter would affect injectors. May affect full hp performance or something else like CP if required for cooling, lubrication, etc. At least the 2nd gens crappy lift pump problems didn't wreck the motor.

:-laf

OK, enough complaining. There must be some high mileage 06 models out there with no fuel problems and factory setup. Hopefully the vast majority will be in this camp some day. Fixing them and not "loving" it. :-laf

 

[TMoe]

As far as factory warranty and adding 2 micron filter. First ask the dealer what they think, denied probably for added restriction, whatever. Carry original hose and wrench to unbolt from airhorn, if you don't have the APPS there. Should take 10 minutes, OK 20, to remove bolts and clamps and add original hose back. See GDP kit.

 

[hhranch]

Jake Brake Warranty

I checked with the dealer from whom I bought my Jake Brake. I was told if it is installed by a Chrysler/Dodge dealer than the warranty on it is the same as on the truck, the remainder of 36 months or 36000 miles. If the truck has over 36000 when installed the warranty is 12 months or 12000 miles.

 

[Jaysyl]

FLOTHO; I had the #3 injector go bad on my 05. I was just going down the HWY about 70 or 75mph. You are right, there is now way to tell. Every thing looked good EGT ,and oil pressure were fine until I stoped at the top of an off ramp and my oil pressure went to zero and i saw the rear window of my A. R. E. cap was covered with oil. . My crank case filled with fuel and blew out the crankcase breather tube. Oil was dripping from the underside of the truck it was a mess. The dipstick was 4inch over full. Just 20 miles before this I was at a Friends house moving his trailer and there was no sigh of what was about to happen.



This was fixed under warranty at 15000, replace the injector. Now 1000 miles later the truck is running better than every. It does not seem if any thing else was hurt. GOOD luck with your 06.

 

[CTRice]

Is this a Fuel Filter problem??

A recent growing problem seems to be injector failures. It seems to me that I read that Bosch recommends fuel filtration of 5 microns absolute to ensure injector longevity. Why has Cummins/Fleetguard and DCX been installing 10 micron filters in our expensive CTD's??



Recently, Cummins/Fleetguard revised the replacement filters. They had a robust looking 10 micron filter and replaced it with a new design that they claim is a 7 micron filter. The new "improved" filter looks poorly designed and has the filter pleats simply edge glued to a flat plastic top and bottom. The old design had flanged ends with the pleats bedded in an elastomeric compound. In addition, the old design was clearly marked with Fleetguard and Stratopore logos.



Why can't Cummins/Fleetguard provide a robust 5 micron drop in fuel filter cartridge?? Why should we be forced to add redundant filtration systems on trucks that already cost most of us $35,000 to $45,000???



Chuck

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2006 Laramie 3500 QC SWB 4x4 48re 4. 10 gears