A little story before I explain the issues I'm having.

In August of 03 I purchased my first REAL diesel truck. It was an 04 Dodge 2500 SRW 4x4. It had the 305 motor with auto. Great truck... the best truck and diesel that I have ever owned. I put 93K on it in that short time NEVER had one issue with it. NOT ONE!!!! Had a recall on a trans line and that was it! I had that thing bombed with exhaust, stacked a EZ and a Bully Dog down loader, cold air intake..... JUST LOVED IT. As time went on, my towing needs changed and I made a choice to trade for a Dually. I have a buddy that I purchase my trucks through and he was able to get me the EXACT SAME truck (even the same color) only difference was that it was a dually AND it was the 325 (04.5) and only 70K. The trade cost me 2k and figured that the added warranty miles would be worth it along with the fact that the body was in GREAT condition - my truck had a couple of dings.

Now for the problems... Had the truck for the first month but it was with the dealer for 3 of the first 4 weeks. Had a bunch of leaks around the oil pan. They never really fixed it, but I know that they've replaced the pan gasket and timing cover gasket - they are trying. Got the truck back and it was making a pretty good popping sound. Turns out that they had to replace a burnt valve. Now it seems to run like a champ.
Dropped off the truck the other day so that they could attack the oil leak AGAIN and wanted them to look at a couple more problems.

PROBLEMS:
1. Oil Leak
2. White smoke at start up - more than normal
3. Raw diesel type smell at shut down or when running - even after white smokes stops.
4. Horrible milage - stock tires w/3:73's and camparatively to my old 305 with 4:10's and 35's with a 4in lift. My old truck got 16 - 17 and this truck gets 13 on the highway.
5. When towing heavy, and when i'm REALLY into it, the truck will surge or mis. Acting very much like a lack of fuel.

Now I will tell you that I have added a brand new EDGE Juice w/attitude since I got it back the last time. I tow only in Tow mode or Stock. I'm telling the truth on that one.

I am very luck in that my guy doesn't care what I have on the truck as far as mods. I'm sure that If I burn down the motor, I'd have an issue...

Picked the truck up the other day, and they told me that it's being over fueled (they think), and to take the box off and check to see how it performs. The box has been sent back and is perfect from edge. It's been updated, and cleared to be in perfect condition. They think that the over-fueling is putting diesel in the crank case causing the oil level to be high thus pushing the oil out of the pan and affected areas.

Now my questions...

while I'm sure it's possible, I don't think this is the case. I think I have a leaking injector, and or a supply pump that is going out. What kind of advise can you fellas give me? One thing is for sure, I sure miss my old truck.

 

I would take it back and have them test the injectors also you can do a oil analysis to see if there is fuel in the oil. Over fueling on a truck that is working properly you should see black smoke on acceleration and high EGT's without supporting mods (turbo, etc). It sound to me like bad injectors which could also explain the burnt valve.

 

That's exactly what I thought. Problem is getting them to believe you or have them respect my opinion.

Guess I'll have to grenade a motor before they do something.

 

I bought an 04.5 with 2 scored pistons, had to overhaul it and have done several 05-06 engines since then from bad injectors and dropped valves. I would say you need to have your injs. checked. If they cannot help you, you can PM me I have a flow bench to test the injs. I can also rebuild them if needed.

 

That may be where I need to go. While I've never done injectors on a Cummins I'm liken' the way you're thinking PUMP.

How difficult is Injector R&R?

 

They are easy to R&R. Take the lines,valve cover,fuel tube nuts,fuel tubes, electrical conn. on top of injs. EXTHAUST rockers,the two inj. hold down bolts off and pop them out, and keep everything in order. I have checked 2 sets already today and have to rebuild one set.

 

Sounds fairly easy. I've just recently (month or two old) purchased a 97 Honda Civic to drive everyday. This will be a great project to start without messing around with the dealer. I'm going to give them one more chance next month and see what that yields. If they don't step up, it will be done right with me.