Remanufactured Engines

[CVR222NV]

I lost the rings and/or piston in cylinder 4 and rather than just repair cylinder 4 I'm giving serious thought to getting an upgraded remanufactured engine. I have looked at a lot of options but the one which allows me to determine some of the upgrades is the Tow/Haul remanufactured 5.9 from DFC Diesel out of Edmonton, Alberta, Canada. The biggest upgrade is the use of 2003-2004 pistons. The other big factor is the warranty.

Cummins Engine Rebuild Edmonton ǀ 5.9 Tow/Haul Series ǀ DFC Diesel

Does anyone know of any other options?

 

[Tuesdak]

If you are worried about pistons get the steel slugs. I never ran them, but, I would if I ever did another engine because they can survive a aluminum piston melting injector failure. MAHLE Motorsports 9299693 Extreme Duty Monotherm Pistons. Nevada outfit for piston reference:

https://www.xtremediesel.com/mahle-motorsports-9299693-extreme-duty-monotherm-pistons

I have run Total Seal Gapless (2nd ring gapless) rings in my 2003 5.9 and a very dirty 6.2 GM diesel. I would call Total Seal and ask who is a reseller in your area. They recommended a great shop that would install them in a build for me this way if I ever did another engine. Cleaner engine oil and less blowby. I doubled the 2500 mile oil change on my 6.2 by using them and the oil wasn't jet black immediately after changing the oil. Most shops don't understand these rings and are scared of them. (I said build my engine this way and some heartburn when it wasn't done the way I asked in a shop that is Good Riddance out of business now.)

That shop that is out of business was local. I drove to the owner's home and knocked on the door when I discovered a serious low oil pressure problem in just 500 miles after the rebuild. They used the old oil pump and the relief valves behind the oil filter assembly were chattering loudly at times. Can you do that for a Canadian outfit, Eh? Looks like a nice build otherwise.

 

[2Farr]

Just had an engine built be a shop in Tacoma Wa. Their name is Outside Machine. He builds all kinds of heavy duty semi truck engines. He works on the small cummins, 5.9 and 6.7 engines. Mine got main and head studs, new head that was ported, he resized the rods after they were shot peened, bored and torque plate honed the block, fire ringed the head, installed a colt stage 3 cam, balanced the rotating assembly. He also can ceramic coat the pistons. There are a few other things that was done to the engine also. The engine been in the truck over a year now and I have pulled my fifth wheel and nothing to complain about.

 

[CVR222NV]

If you are worried about pistons get the steel slugs. I never ran them, but, I would if I ever did another engine because they can survive a aluminum piston melting injector failure. MAHLE Motorsports 9299693 Extreme Duty Monotherm Pistons. Nevada outfit for piston reference:

https://www.xtremediesel.com/mahle-motorsports-9299693-extreme-duty-monotherm-pistons

I have run Total Seal Gapless (2nd ring gapless) rings in my 2003 5.9 and a very dirty 6.2 GM diesel. I would call Total Seal and ask who is a reseller in your area. They recommended a great shop that would install them in a build for me this way if I ever did another engine. Cleaner engine oil and less blowby. I doubled the 2500 mile oil change on my 6.2 by using them and the oil wasn't jet black immediately after changing the oil. Most shops don't understand these rings and are scared of them. (I said build my engine this way and some heartburn when it wasn't done the way I asked in a shop that is Good Riddance out of business now.)

That shop that is out of business was local. I drove to the owner's home and knocked on the door when I discovered a serious low oil pressure problem in just 500 miles after the rebuild. They used the old oil pump and the relief valves behind the oil filter assembly were chattering loudly at times. Can you do that for a Canadian outfit, Eh? Looks like a nice build otherwise.

Looks like they use Mahle Motorsport pistons in their race engines so I can check. Probably a lot more money! Do they make them for the 2003-2004 piston design?

I'll inquire about the rings.

Yeah you hit the nail on the head about local shops. I could probably find someone to do a rebuild but I have found nothing so far that approaches the machining done by DFC Diesel. No complaints on BBB and they offer a warranty. But this is why I have posted this thread to see what my options are.

 

[CVR222NV]

Just had an engine built be a shop in Tacoma Wa. Their name is Outside Machine. He builds all kinds of heavy duty semi truck engines. He works on the small cummins, 5.9 and 6.7 engines. Mine got main and head studs, new head that was ported, he resized the rods after they were shot peened, bored and torque plate honed the block, fire ringed the head, installed a colt stage 3 cam, balanced the rotating assembly. He also can ceramic coat the pistons. There are a few other things that was done to the engine also. The engine been in the truck over a year now and I have pulled my fifth wheel and nothing to complain about.

Did you get a warranty?

 

[AH64ID]

I would not look at steel pistons. Sure they don’t melt, but there are reasons pistons are aluminum alloy. The cold weather behavior, among other things, make them more of a race only piston.

Even if you get a stock 03-04 HO long block it will be much better than a 04.5-07 long block, but if you can find someone who installs the QSB 480 pistons it will be the strongest.

DFD does look like a good option. Have you seen the maintenance requirement for the warranty? What’s the difference in tow and towHD?

For your use you want to avoid fire ring and o-ringed heads, the stock MLS gaskets with ARP’s is more than strong enough.

 

[CVR222NV]

DFC Diesel is recommending this intake manifold that requires some machining. Manufactured by Hellman for DFC Diesel. Different than the Hellman side draft as it allows all components to be a direct bolt on. Benefit is better air to cylinders 1 and 6. Thoughts?

 

[AH64ID]

My 0.02 is that you likely won’t get much ROI on the power levels you plan to run.

 

[Tuesdak]

I would not look at steel pistons. Sure they don’t melt, but there are reasons pistons are aluminum alloy. The cold weather behavior, among other things, make them more of a race only piston.

What am I missing?

http://blog.diamondracing.net/behind-the-scenes-diamonds-steel-piston-technology-

http://www.trucktrend.com/how-to/expert-advice/1211dp-aluminum-vs-steel-diesel-engine-pistons/

 

[AH64ID]

What am I missing?

http://blog.diamondracing.net/behind-the-scenes-diamonds-steel-piston-technology-

http://www.trucktrend.com/how-to/expert-advice/1211dp-aluminum-vs-steel-diesel-engine-pistons/

As both those articles mention they are for extreme applications and severe duty, they don't talk about DD or towing applications. There are certainly benefits to steel pistons in those extreme/severe duty applications, but they do have drawbacks. Steel is slower to expand under heat so on cold motors they get more blowby, they are also heavier so you lose economy and increase internal wear.

Mahle doesn't make 03/04 bowl style steel pistons either... might be nothing but I read between the lines that the 03/04 bowl doesn't have the issue like the 04.5-07 bowl does with melting. They also don't make them for the 12V 5.9's or the 6.7.

 

[CVR222NV]

AH64ID and Tuesdak thank you for the input. I posted this thread so I could get educated and certainly want to make an informed decision.

This is the Cummins 480HP QSB OEM Piston ($1320 for a set of 6):

Dodge 24 Valve Cummins 480HP QSB OEM Piston Kit (puredieselpower.com)

Maybe Mahle does make a steel Monotherm piston for the 2003-2004 5.9 ($3943.38 for a set of 6):

Mahle Clevite Piston, (2003-04) Dodge 5.9L Cummins Forged Steel Monotherm (ktperformance.net)

Here is a set of 6 but not sure if its the same piston as above ($3137.25 for a set of 6):

Mahle PowerPak Performance Piston and Ring Kit, Set of 6 (03-04 5.9L 24v) (ktperformance.net)

This article was referenced in the second link Tuesdak provided:

Mahle Unbreakable Pistons: Piston Of The Future (trucktrend.com)

I'm going to find out exactly what piston DFC Diesel is proposing to use in the build. I told them right up front I did not want to go down the race engine rabbit hole. The engine as currently proposed already costs enough to choke a horse!

 

[AH64ID]

Maybe Mahle does make a steel Monotherm piston for the 2003-2004 5.9 ($3943.38 for a set of 6):

Their 2020 catalog only lists 1 steel piston (for all Cummins 5.9/6.7, Ford, Duramax applications). It states 03-07 5.9 CR engines, and that you must use a 04.5-07 injector.

 

[2Farr]

Did you get a warranty?

Two year 200k on the engine. Five year 500k on the trans

 

[CVR222NV]

Their 2020 catalog only lists 1 steel piston (for all Cummins 5.9/6.7, Ford, Duramax applications). It states 03-07 5.9 CR engines, and that you must use a 04.5-07 injector.

Looks like you are correct that the Monotherm steel pistons listed for the 2003-2004 trucks have the 2004.5 bowl design:

2003-2004 5.9L Dodge Cummins Mahle Monotherm Pistons (dfcdiesel.com)

 

[cerberusiam]

The only that looks to be missing is info on rods. Wonder if they are addressing that somehow.

 

[CVR222NV]

The only that looks to be missing is info on rods. Wonder if they are addressing that somehow.

I'm assuming you are referring to connecting rods? Not sure what they are using but will ask. What do you recommend? Any problem with using connecting rods from the core engines they receive?

 

[cerberusiam]

If they are cracked cap, I would replace them. Aside from the expensive racing ones, most use a set machined forged 24V rods so the rotating assembly can be balanced.

 

[CVR222NV]

Got the motor pulled:

Never thought I would see this view of my Cummins:

I stripped the motor down to the long block:

Motor is ready to ship.

 

[CVR222NV]

Since I already had the motor stripped I decided to pop the head to assess the damage. Piston #4 and cylinder wall not looking good.

The remaining pistons and cylinders look like this:

Here is a shot of the valves. Carbon build up on #4:

Going to button it up and get it ready to ship. Any comments?

 

[AH64ID]

Looks like that hole got warm?!