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Engine/Transmission (1998.5 - 2002) Problem after Dealer Worked on Truck

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2nd Gen Non-Engine/Transmission Straight piped

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I actually have two problems that started about 6 months ago. Here is the order of events.



1. High Pressure Pump replaced by dealer with factory rebuilt one. Approx 1 year ago.



2. Clutch replaced with new one from TST 6 months ago.



(After getting the truck back after the clutch replacement notice slight occasional miss in engine. Very minor but especially noticeable when standing by the exhaust pipe. )



3. Last month take truck in because Tach keeps dropping to zero but it runs just fine and doesn't seem to affect the driveability of the truck at all.



4. Dealer says it is a bad Crankshaft Position Sensor and also a bad MAP sensor and they replace both. I get the truck back and notice a surging problem at 1400 RPM 1600 RPM and 2100 RPM. I also notice that unlike before the Tach needle jumps in about 50 RPM increments when accelerating or even at idle when racing the engine. Rock solid at idle. At 1600 RPM it fluctuates about 100 RPM.



5. On my own I buy a second MAP sensor and replace it and also pull out my DD3 injectors and have them all tested locally. Neither of these things make any difference. I also checked all the wiring on the MAP sensor leads and on the Powermax 2 box. I even removed the PM2 and still had the problem.



6. The other night while is was idling I sped up the motor some and the ABS light came on for a second then went off.



My main problem is the surging which is really irritating but I also would like to fix the slight miss. I tried taking it back to the dealer and they said they didn't know what it was. They act baffled by my modifications.



Truck Specs:



98. 5 24v 5 speed, Reflashed ECM by TST, PM2, DD3 injectors. Rear ABS only.
 
Wish I could help you out man, but I really know little about the crank sensor. Did the dealer say anything about you having that PM 2 hooked up?? I have a PM 3, and a pusher pump back at the tank, but I think my lift pump is going bad, would like to get it replaced under warranty.
 
Yeah, they have made coments about the PM2 and basically look at that and try to blame it whenever something isn't running right. LOL I moved my lift pump back to the rear by the tank also. I seriously doubt if the dealer will replace one that has been moved but I think it depends entirely on the dealer.



Keith
 
Well, after climbing around under the hood some more it seems that I have BOTH a crankshaft AND camshaft position sensor. I also noticed the dealer had left both negative battery terminals loose. Could this be causing my problem? I tightened them up and just driving around the driveway a little I didn't notice it. We will see tomorrow.



Keith
 
The 98. 5's had both crankshaft and camshaft sensors. I think they dropped the cam sensor starting in 99. I had wierd idle problems caused by leakey injectors but the tach did what you expected it to. I cured the leakey injectors by pulling them out and replacing the little copper washers with new ones and re-torqueing everything carefully.
 
Well, I am taking the truck back to the dealer tomorrow who said the last time I had it in their usual diesel guy had been off for a family problem and they said they wanted the regular diesel mechanic to try and see if the other guy did anything wrong of if there are any error codes. If this doesn't work I guess I will call Cummins and see if I can get them to check it out.
 
Well, I took the truck into the dealer today and they said they could feel the surging but didn't know what to do since they checked for codes and got none. They also reset all the valves. I went and picked it up and after driving about 5 miles the problem got much worse to the point that it almost would accelerate off of idle then when it went to idle it would surge up to 2000 rpm without my foot on the accelerator. This finally tripped a check engine light and I turned around and limped back to the dealer at a snails pace. When I parked it in the lot and got out the truck was idleing anywhere between where it usually does and 2000 RPM and the mechanic came out and just shook his head and I asked if he believed me now? :rolleyes: He said the diesel guy had gone home and didn't work again until monday but that they could do basic stuff like getting the error code and replacing sensors without him. I am dying to know what this is. Part of me is thinking the accelerator position sensor but I replaced that about 2 1/2 years ago and when it went bad the truck would idle just fine.



Keith
 
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