BigBlockDaddy

Hi folks, new to the site.
My father in law has a 2006 3500 Dodge with a 5.9 that wont start without a shot of starting fluid. We had it at the dealer around 80,000 Kms ago for some issue or other and at that time they replaced the injectors. The extended warrenty is now over as the truck has 190,000 Kms on it.
For the last several months, we've been trying to solve a hard start problem. Several mechanics gave us different opinions ranging from the pumps to the injectors. To date, I've changed the pump in the tank, which I believe is called the lift pump, the primary pump on the engine and I've also changed 4 of the six injectors.
When the lift pump was changed, it started fine for a few weeks. The problem returned.
When I changed the pump on the engine, the truck started fine for 1 day. The problem returned.
I find the engine cranks really fast, which seems odd to me. One mechanic, from cummings, told me it was either the primary pump or the compression. I can't see a newer truck having lost its compression. No cracks in the air box or air systems. The engine runs fine, no smoke once its running.
My plan now is to change the two remaining injectors and see what happens. Anyone have any idea as to the problem?
Thanks.

Lost Lake

Check the fuel supply. You need lots of fuel or it won't start. I don't remember how much, like 700 ml in a minute.....

Hvytrkmech

What is the rail pressure? Did you check the rail pressure relief valve?

BigBlockDaddy

I will check the rail pressure when I get back in a couple of days. Where is the RPRV located? I'll do a bit of research and check it out. Thanks a bunch.

krh

well im the bearer of bad news.
I have an 05 with 210km on it, and i had half of the rings broken out of it.
Wouldnt start without ether, idled poorly but ran great on the highway.
have you had a bunch of oil leaks spring up? Is the belly of the truck all oily?
give it a huff of ether, start it up and take off your oil fill cap. Odds are it tries to blow it out of your hands.
If your near calgary AB I could give you a hand, Im actually a diesel mechanic and Im just about to get my block back from the machinist this week, so I feel your pain. PM me if you want to know prices i paid and who i dealt with, I got a pretty good deal.

CoastalDav

Sorry to hear about the engine. There has been lots of discussion on the form about engine wear and specifically, rings that have failed. Yours seems to be the worse I've heard of here. Most were one or two rings that failed.

What type mods did you have on the engine?

What type air filter were you using?

Did you do alot of towing or just used it as a commuter?

Anything else you might have done that would not be good for the engine?

If you would, when you rebuild, keep one of the rings that failed. Let me know when you have it. If you don't mind, I might want it to do some testing on. Burnell Hardness, and compare it to earlier rings in cummins engines.

I think there is a material problem with the rings in the 03-07 5.9's.

Dave

krh

https://www.dieseltruckresource.com/...y-t255200.html

thats the thread ive got going about this whole issue.
Give you the rough run down
bought it in may, got about 15000 km on it and it wouldnt start or idle properly anymore.
I'd switched to baldwin air and fuel filters, fleet gaurd synthetic oil filters and chevron synthetic 5w 40 Delo 400
had both rings on number one broken into small pieces, 2,5,6 had the top rings broken. 1,2,5,6 had scoring in the barrels, had to go .5 mm oversize. Number 5 rod bearing had picked up, ground my crank mains and rods to .25mm undersize.
Ive found scoring on my rockershafts as well. Cam and oil pump seem to be in ok condition, no major scuffing on bearing surfaces.
Motor and tranny are stock it seems, smoked alot of black and had real good power but no programer or anything i could find. All i found was one of those little crappy enerstar fuel line things. Dealership said they doubt the last guy would do anything like program his truck, especially an aggresive tune like i think it had.
Used it only for commuting and box loads as i had no time to get the trailer id intended on.
I always warmed the truck properly, didnt over rev it, and kept good oil in it.
I have to admit that the thick black smoke it could produce was used to educate a few people about my opinion on their driving habits tho. PM me an address if you want, i never throw parts away until the job is done and out the door so ive still got all my ring bits. I can send you some in an envelope if you want.

XLR8R

Ether is one of the best ways to break compression rings.