Engine Has Flutter Under Moderate To Hard Acceleration

[CRiggan]

My truck is an 05 Ram...



My truck was running great untill I blew the intercooler hose off from the intake due to improper fit to ATS arcflow. At the time I blew the hose off, I had a mp-8 module turned up to 90% stacked with a TST on 4/4.



I put intercooler hose back on , went out for a drive and now I have a flutter.



Here is what I have done so far...



Sent off turbo, checked out ok

Sent off cp3 pump, upgraded it Rail pressure is great

sent off TST module for check for proper operation, checked out ok

Sent off injectors and connector tubes for check, checked out ok

Reflashed ECM with latest software available

Re plumbed fuel lines from tank to cp3 with fass 150 filters and pump

replaced fuel filter

reset valves, although they were very close in spec.

inspected push rods using roll method, ok

visually checked all overhead including valve springs, ok

engine oil color and level is ok

coolant color and level is ok

fuel lift pump pressure is 21psi, checked continuosly with manual gauge, ok

checked for boost leak with turbo boost pressure tool, no leaks, ok

installed head studs torqued to 125 lbs and retorqued again at 125



This condition presents itself above 25psi of turbo boost and when adding more fuel than stock levels. Like tst on 3/3 or 4/4.



Feels

 

[Got HO?]

It may be worth checking driveshaft u-joints. If they have a tight spot it tends to be worse under high torque conditions & will shake the truck, feels like a misfire at times... , particularly between 30-70 mph.

 

[CRiggan]

just had the driveshaft replaced about 3,000 miles ago due to driveline vibration. This is defenately different than a vibration .





It is almost like the exhaust pulses out of the exhaust manifold into the turbo are not in sync. I wonder what a valve staying open or closed too long would sound like under hard acceleration?

 

[Russellmag]

I had a pretty loud flutter sound and it ended being the head gasket? It sounded like the plasitc piece under the hood was flapping.

 

[CRiggan]

I found one problem but it did not help as much as I had hoped. I checked my exhaust manifold gaskets and all was great. The gasket between the turbo and exhaust manifold had burt the outside edge almost into two pieces. I had a small leak there. Re installed new gasket, test drove, and nope, the flutter is still there and just as strong as before.



This flutter is not a flapping sound or metal sound. Its like as soon as boost comes above 25psi or so you can hear the motor loose its smooth acceleration and start fuh fuh fuh fuh flutter. Power is almost there if it could loose this fuh fuh fuh. Not really a misfire and the DRB III shows no codes and all tests are great. The injector kill test proved the injectors are all working and the contribution test are all right at 100 percent.



I am wondering about the stock intercooler and hoses, although they did pass my manual boost test with cold shop air at 30 psi. I wonder if went this air is heated under engine load would my stock all metal intercooler be creating the problem or stock pluming.



Im clueless.....

 

[CRiggan]

Everyone has been extremely helpful thus far. . Have a small question.





I wonder if my fuel rail may have trash or problems. checked all fuel lines and hard plumming and its in tip top condition.



What could I flush out my rail with if I were to remove it ?





going out on a limb here...

 

[CRiggan]

Starting to get a little desperate for some feedback here or next item to check on the list.



I checked the plumbing from the turbo to the intercooler to the engine and found no problems.



I went ahead and replaced the entire plumbing and intercooler with a used banks technicooler that I had stored away for a later date. Thought I might fix any leaks. No problem here , everything working good with my used technicooler and plumbing but I cannot get rid of this flutter. Im starting to think I may have an intake lifter that is not working correctly or a problem with the valve seating. Its hard for me to draw this conclusion since the truck gets very good fuel mileage about 16 to 18 mpg running 70 mph with 4. 10 gears. Idles great but under moderate to heavy throttle I have an engine miss or flutter. Transmission checks out just fine.



My items to do on thursday consist of pulling the exhaust manifold and checking for possible burnt/leaking gasket. Problem is I cannot hear an exhaust leak or see black residue around any cylinder port.



Engine oil and level checked ok again today. By the way the highest i have ever seen the EGT's for a moment or two is around 1370 and Im talking hit it and backed off fuel.



Has anyone had or know what the engine will run like with a bad lifter?



Could a TST injector harness cause this issue?



Im going back stock also tomarrow, TST coming off and stock air box going on so I can do more in depth diagnostics.



This sucks, but its play to pay or pay to play for me each and every day I can now say and by the way Your help and comments do help Please reply with any info you have even if it is a





... Sorry dude no help here but I can tell you that you are up **** creek without a paddle.



Good news is I still know how to swim Thank you all for your help !!! TDR is a great place to be. .

 

[Got HO?]

Have you done a compression test?

 

[CRiggan]

No, but I have done an injector kill test and a cylinder contribution test and the cylinder contribution test showed every cylinder at 100 to 95%. Brett had told me that it cannot be below 86%