Injector Failure

[AEpley]

I have a 2007 Dodge Ram 2500 with the last of the 5. 9L Cummins engines. I have 106K miles on the truck and have had 3 injector failures. It is stock. Has never had programmer on it to increase fuel mileage. Fuel anaylsis done at dealership shows clean fuel. I have only towed twice with it and then the load was 1500lbs. Original warranty covered first 2. The last failure Dodge paid the labor but I had to buy the injector.

I love my Dodge truck but cannot continue to replace injectors at almost $900 a piece. I contacted Cummins who says that once Dodge puts the program on computer of engine they are not responsible. Dealership says fuel pressure checks within tolerance. Any suggestions from anyone.

 

[Prairie Dog]

A good 2 micron fuel filter will help to protect your injectors from the fine dirt that wears on them. Do you know if the failures were electrical?

 

[AaronOregon]

A good 2 micron fuel filter will help to protect your injectors from the fine dirt that wears on them. Do you know if the failures were electrical?

X10! Cummins CAT Fuel Filter Kit. CHEAP INSURANCE against this!

 

[Prairie Dog]

Glacier Diesel makes a nice system as well: Glacier Diesel Power

 

[AH64ID]

OEM min filtration is 7um, Bosch recommends 5um, and many (including WIX/NAPA) filters don't even meet OEM min spec.

Glacier is who I would look into for filtration, the Cummins Cat kit is a well built kit, but I would look for one that puts the "2um" filter after the OEM cansiter.

I put 2um in "" because based on modern standards there are no 2um filters. The cat filter listed is 4um, the GDP FF5320 is 5um, and the Donaldson P551313 is 3um and they all fit the same head.

The link in my sig shows the setup I have.

 

[TCDiesel]

Clean fuel Is NOT the OP problem its those who have finger printed His repairs,OP you will continue to have injector problems until ALL are replace at the same TIME. It a vicious circle of repairs,Some may replace 1 or 2 and and its seems that fix the problem ,only until the next failure, the process just continues, Look at it form this angle ALL 6 injectors share the forces that the the CP3 creates, AT X point they drop below specs, now replace 1 or 2 it raise above the spec,Now the problem is these 2 will be above the other 4, How long before these New 2 drop to the other 4. This is as simple of an explanation and I Can type. You have 6 married injectors, replace 2 and now you have a divorce with 2 married and 4 adulters... ... .....

 

[CKelley1]

the injectors were worn because of lack of filtering, put the 2 micron filter on before the stock filter, this should save the three new ones and extend the life of the other three a little longer. you can build the dirty filter setup for $60 this includes filters.

we mount the filters just forward of the fuel tank. we run a fleet of dodges and recently installed one on a 06. there is two bolts through the floor board for a rear seat option at this location. some of our trucks use them others do not. get a 2" x 3" piece of angle iron 6" long. make a card board template that the two bolts and keeper nuts will go through hold the template on the inside against the 2" part and drill the two holes they will be about 5/8" i think and about 3 7/8 " between. center the holes on the 2" and near the edge on the 2" hold the angle iron over the bolts with the 3"part the furtherest away from the tank and drill a 1/4" hole between the two holes, keep drilling through the floor board. now after you mount the filters to the angle iron just simply mount it with a 1/4 grade 8 bolt. this is the only hard part the other items is easy. the total time including building the bracket is about 1 1/2 hours. i will give you napa numbers but they can cross reference to wix or car quest. the two bases are 4770 the water separator pre filter is 3374 if you think you must have a drain on the separator use 3406 the 2 micron filter is 3674. use a 3/8" nipple with about 1/2" space in the middle connect the two bases together observing the in and out. because of this the mounting plate on one filter base is about 1" further out than the other. install two 90* 3/8" barbed fittings on the bases and temporary bolt the angle iron up and hold the filters up to it. make sure everything clears and mark the one base that touches the plate to drill the three holes to mount the filters. next cut the feed fuel line at this location and bend the lines out a little and install 3/8 hose over the lines and to the barbed fittings. i put a small amount of flair on the steel lines. but i do not think it is necessary. Bleed the air out through the stock filter before trying to start it. use a gauge and do not change the filters until you see a four pound drop this should be about every 150,000 miles and the stock filter will never need to be changed. Cheapest place is Wix Filter Bases: FleetFilter Secure Online Store



your filter base has two inlets and two outlets on each base be careful to connect the nipple between the outlet of the first filter to the inlet of the second. only one of the bases get's the bolts as the offset places the second base about a inch away from the plate. we use to make spacers on the first ones and then decided they were not needed



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[Prairie Dog]

This thread is turning into a bad deja vu...

 

[TCDiesel]

No its just the same Band wagon... Most members and guess Have NO understanding of CR systems... Lack of filtration is By far the 1 reason of Failures. . Couple that with the lack of understanding just complicates things more. I'm all for more filtration but it doesn't apply for every failure. the cycle I mention just keeps repeating itself over and over. I paid BIG TIME until I stop warranties Parcel sales. . I will ONLY sell Injectors with warranty on set of 6. Its unjust knowing that it in most cases it just prolongs the emanate replacement of the 6.

 

[AH64ID]

Clean fuel Is NOT the OP problem its those who have finger printed His repairs,OP you will continue to have injector problems until ALL are replace at the same TIME. It a vicious circle of repairs,Some may replace 1 or 2 and and its seems that fix the problem ,only until the next failure, the process just continues, Look at it form this angle ALL 6 injectors share the forces that the the CP3 creates, AT X point they drop below specs, now replace 1 or 2 it raise above the spec,Now the problem is these 2 will be above the other 4, How long before these New 2 drop to the other 4. This is as simple of an explanation and I Can type. You have 6 married injectors, replace 2 and now you have a divorce with 2 married and 4 adulters... ... .....

I would say that clean fuel could have been an initial issue, and should be corrected to prevent future issues from contamination since we know OEM is barely, if that, adequate. It may not have been, but it generally is.

I agree on the latter, always replace in sets of 6. Some say you can do 3 if you do the proper 3, I think 1-3 or 4-6, but all 6 is the best bet.

Unfortunately Dodge will not just replace 6 when 1 fails anymore, I guess they figure 1 or 2 will get you out of warranty then it's on your dime.



For the OP, now that you are out of warranty stop going to the dealership, they will rob you of far more money than you need to spend.

 

[S.Morris]

I also recommend all 6 if you want to keep down time to a minimum. If you have lots of time or lots of money, and love working on your truck , do them one at a time.



I would also suggest buying your set of 6 injectors from someplace like T&C because his prices for NEW injectors are half the price for remans at least here in the Great White North.



I recently changed injectors one of our service trucks(an 03 )Gained a couple of months by retorquing cross tubes before the injectors. This truck had 8240hrs on original injectors and now runs/ starts like new again.

 

[EDankievitch]

The dealer is probaly using reman injectors and not all remans are of the same quality... .

 

[SWithrow]

cannot continue to replace injectors at almost $900 a piece.

WOW, $900 a piece... my understanding is the stealership uses remans. Injectors for your truck (NEW) are around $460 +/- depending where you purchase them.

 

[AEpley]

Thanks for the suggestions. I bought the Cat/Cummins Fuel Filter System. The instructions are very easy to follow. I installed this. Time will tell if this filter helps the problem.

 

[KIKER]

Two replacements got me out of warranty and the third cost me dearly. They were all on the 2nd bank, 4-6. My truck was at 102,000 on the third and they didn't cut me any slack. I'm pretty sure they were electrical problems. The last one was, I'm sure.