Haulin_in_Dixie

It was the middle of the night, raining, cold, no heat and I was tired as all get out. I pulled a real bad hill loaded and near the top noticed that the engine temp was up near max/safe. EGT gage has not been working right.

Later I noticed a noise, finished another 300 miles and went home. This morning it started with a belch of blue smoke than which went away. Has a hammering sound on pull and idle. Runs ok, pulls good, no miss. Maybe a bit of more blowby. It is number one cylinder, cracking the injector line makes the noise go away. Did I melt a piston?

Had to cancel several loads, hope I keep the customers :'(

Ok, if I did melt a piston, will the cylinder wall be ok and just need the piston replaced, or am I into a rebuild?

Feels dumb, I was just too tired and uncomfortable to be driving.

Mexstan

Before pulling the engine apart and guestimatimg at the problem I would do a compression check. Do this and let us know the results.
If you melted a piston it is doubtful if the cylinder walls are damaged. If you broke a piston ring, that could damage the cylinder wall but the not very likely.
Also check your water level in the rad. And the color of the water.

RCW

The symptoms sound very much like a piston problem, but it could be the tip of an injector is burned and causing the problem.

To save bucks, I would pull the injector and inspect the tip. If it is burned, replace it and the problem should go away. Then count yourself lucky and get your pyrometer fixed.

If it is not a burned injector tip, do not start or drive it anymore than you must, and get it into a Cummins Service Center and do a compression test. Most times, the burned piston can be pulled, the cylinder honed, and a new piston installed; as long as you do not score the cylinder wall.

If, by chance it has low compression and needs serious work, be sure you do not have a "53" block before you spend any money putting new shoes on a dead horse.

If you need an engine, check this site for special offers: http://www.cumminsnorthwest.com They frequently have overstock sales on B series 5.9 engines that are new and surplus to their needs, and run about half the regular cost of a new engine.

jdeereboy

I agree with a problem with an injector. Most likely leaking or poping off too early. This would make that cylinder essentially detonate. I doubt that it is a piston problem since it goes away when you crack that line. Can try swapping that #1 injector with another one on the engine to see if the problem follows that injector.

Haulin_in_Dixie

My intentions are to pull the injector and put one of the stock injectors in to try it. It would fire a little weaker but should do for the test. Next I will pull the pushrods on that cylinder, just on that chance. After that I can see nothing that could be a problem that the head does not have to come off.

I have no access to a compression gage for it. The engine has always had more blowby than I feel is normal, especially on cold days when you can see it the most. The antifreeze is pretty blue, there are no oil leaks, it has used no oil since the problem started. A burned piston should cause more problems than this shows, I would be shocked to find that it is a rod bearing, it is a single knock, not double, oil pressure is normal. It seemed to start from getting the engine hotter than I have ever had it, the grade was probably 8 plus and I was loaded heavy, distracted by the no heat, pain in my leg, fogged windows... bad night, did not notice it getting hot.

I did notice one thing early today while testing, the knock seems to diminish at higher rpm's. Sounds like my best chance is the injector. Maybe I will luck out.

thumper 549

I have 6 pistons if you need them (used)

Lil Dog

Pull some oil from your filter for an oil analysis. If you have done it in the past you will know what your aluminum and Iron levels were. If those level have shot up, then you may be concerned about the piston.

If the fuel dilution level has shot up, or some of the soot level, the injector may be a cause.

If none of the levels have changed much, then you may have a mechanical problem.

Just a thought to avoid teardown...

J-eh

Haulin_in_Dixie

Well it looks like my back is to the wall. I replaced the injector, checked the pushrods, all is well. The rap is still there. Cracking the injector nut eliminates the rap. Unless someone has some great info that I don't have it looks like teardown time. The rap is a high metallic rap.

The service manual says that the pull the pan you have to pull the trans, flywheel and housing. Looks like it would be easier to pull the engine. Some comments would be helpful.

Not a good time, sorta wiped out my business and right at tax and insurance time. Friend of mine always says, "life sucks, then you die." Think he's right about now.

Smokeman

Your good customers will find a way to get by until you get back on the road. Good luck.

Brian

Lil Dog

Maybe you could rent a little rig to get you through it? ???

Might help enough to pay bills and keep everyone happy in the interim..

Chin up, you wouldn't have gotten this far without good work.

J-eh

kd460

Do you plan on pulling the head first to check? Or will you go for broke and pull the engine? Just curious as to what the problem is. Sure would be nice if you could take a few pics while your at it.

I hope you still discover something simple as the cause. Let us know what you discover. Probably not a bad idea to call your customers and let them know about your problem. If they are happy with your service, I'm sure they will understand. These things happen. What about "sub-contracting" someone to do your deliveries till your truck is back up? Kevin

PumpDaddy

Haulin In Dixie, I know less than squat about how to fix the problem, but if you need tools, an overhead crane, and a covered shop to pull the motor (heat ain't so good) but I have a 150Kbtu propane heater that we use, I can move a crap load of pumps and parts to give you room to work on your truck. I've got two 2 ton cranes in the back shop that should be more than enough to pull the motor and a 6K & 4K lb forklift if you need. Or if all else fails, we can just pull it out in the parking lot. I'm in Adamsville, the shop is in B'ham, about 12 miles from home, let me know if I can help. Send me a PM and I'll get back with you.

Terry

Haulin_in_Dixie

First I cannot express how much I appreciate the fine comments and morale boosters in this thread. First off I am not a quitter, the truck will get fixed, I have been known for doing the impossible when it could not be done, I do have the experience although not with the 5.9 and I do have the tools, albeit been a while.

I spent hours going over web sites trying to gain info on this thing, and not sure what I will find, but really expect something with the piston. Wonder if those plastic oil sprayers may have something to do with it. I will probably go for the bottom first so that if the crank is bad the motor comes out. There is really nothing under the head that can be fixed without the pan coming off.

It started all at once which implies to me that something broke, or a bearing spun. What else is left, a broken piston, does not sound like the double rap of a piston pin. The injector was very wet which may mean that that is what started it.

I appreciate all the fine comments and will keep ya'll posted as it gets fixed.

Bill

DPG

Good Luck, Haulin'!

DeWain

thumper 549

the 1st thing to look for is the little green things in the bottom of the pan. If none, your in fat city, all it is ,is a broken piston probly.
If there is piston squrters in your pan then there was not much oil p. to the mains and rods...been there done that, not pretty.
if you need help give me a shout.I have way to much intimate knowledge with mine ...might as well share it.