3rd Gen Engine and Drivetrain -> 2003-2007 5.9 liter Engine and drivetrain discussion only. PLEASE, NO HIGH PERFORMANCE DISCUSSION!

Only Runs On 5 Cylinders...Something Broke

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Old 05-28-2014, 04:18 AM
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I'm no expert, but with a bent rod I'd want to make sure the crank is ok.

If not, I'd wonder if a reman long block might start to make sense, money wise.
Old 05-28-2014, 06:17 AM
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Originally Posted by 1972RedNeck
We did.

We finally got the motor pulled out. It took Dad and I a solid 8 hours to pull it and get it stripped down. It was by far the hardest engine I've ever pulled.

Anyways, here are some pictures of the findings.


Attachment 43057

Attachment 43058

Attachment 43059

As you can see, number two is shot. What you can't tell from the pictures is that in the second picture, we have the piston at the top of the stroke - and it is still down in the hole where it should be almost flush with the deck.

And keep in mind - this is a 70,000 mile truck that has hardly ever pulled anything.
Maybe I'm wrong but to me, it looks like the top of the piston eroded away and the top ring is the highest thing on the side of the cylinder.
Old 05-28-2014, 08:50 AM
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Originally Posted by 1972RedNeck
I don't see what else it could be. The plans are to just do a stock rebuild but swap in a Colt Stage 3 while it's apart. We're thinking about just having the one hole bored and sleeved. Thoughts?
you can just bore it and not sleeve it and be ok.

It sounds counterintuitive to have one hole "out of balance"... but I know of a couple of others who have done this with no noticeable effect.

Not what I would do personally though...
Old 05-28-2014, 08:38 PM
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Originally Posted by soulezoo
you can just bore it and not sleeve it and be ok.

It sounds counterintuitive to have one hole "out of balance"... but I know of a couple of others who have done this with no noticeable effect.

Not what I would do personally though...
That has come to mind but I like to do things the right way. Having mismatched pistons doesn't seem right to me.
Old 06-29-2014, 12:54 PM
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Here's some pictures of the damage. #2 cylinder.





Old 06-29-2014, 01:01 PM
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We couldn't figure out how to get the engine back in with the valve cover and oil pan on. We called the Dodge dealer and they said that they lifted the cab or pulled the oil pan. I was feeling kind of lazy so I broke out the sawzall and cut the cross member core support thingy that goes between the fenders in two so it could be unbolted and slide out. Guess what? The engine slipped right in.

Why didn't Dodge make it removable in the first place? It would have made things much easier.
Old 07-02-2014, 12:11 AM
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The front rad support/cross member on the 3rd Gens is a total PITA.
Many guys cut the cross member and then weld it back together, but I would recommend to fab up a way to bolt it back together, so it will be easier if you ever have to take it out again.

One guy local to me, used straps to slightly stretch the fenders apart, pulled out the cross member, remove/re-install the engine and then stretched the fenders apart to re-install the cross member.
Old 07-04-2014, 09:21 PM
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I welded it back in. If the engine has to come out within the next 400,000 miles, I'll make someone else do it.

We have been driving it around the past few days. When we had it apart, I put a Colt sage 2 cam in it. I cannot believe the difference it made. The added low end is absolutely amazing.
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