Truck acted up last Monday. Strange combination of items to numerous to list. Removed all accessories and used dielectric grease and re made all connections and all seemed well. Today coming home from work did it again. Changed fuel filter, re-greased connections and cleared codes and again all was well. Called dealer and found out I was only a few weeks out of warranty and they said they would try to get it in under warranty. On drive to dealer (35 miles) got to thinking about it and decided that when I accelerated hard was when it did it think. Drove very conservatively to within 1 mile of dealer then floored it and immediately got bad running and codes. Won't know till Tuesday what if anything they can do so looking for any suggestions just in case. It is off the road at the dealer but I do too much driving to have any problems like this. Just in case:

07 2500 4x4 auto 5.9 engine.

 

No thoughts here?

 

Pull the pressure/temp sensor out of the intake manifold and see if it's dirty, if it's plugged it may not sense the pressure change and fuel accordingly.

 

Thank you for an answer. will try same tomorrow.

Don

 

OK dealer I had it at can not do Dodge warranty work and get reimbursed, no certified diesel mechanic , but he did diagnose 2 items. #5 injector and injector wiring harness (may not have this 100% right as I was driving in upper Ohio delivering paint). Ok on to solution, I'm 3 weeks out of 5 year warranty but Chrysler is willing to repair for the $100 deductible. Had to have it towed to another dealer with a diesel tech, 58 miles, but thought it was worth it. They will call me tomorrow am and confirm diagnosis and give me the time frame for repairs. Should be done by end of the week.

No fuel in oil, so must be electronics failed? (question).

Hopefully all will be OK after this. Only at 55800 miles so....

 

Sounds kinda like your wiring harness (which is made into the valve cover gasket) might be messed up....along with an injector. But, you stated no fuel in oil...hhmmmm. I still say it's the wire harness.

 

I agree with the wiring harness, but I'm at the mercy of the dealer unless I want to spend the cash myself. Still waiting for the final diagnoses and don't know when that might be. I find it hard to believe a bad injector as it ran perfect and for an 07 4x4 auto on the highway got consistently 23-24 mpg. Lots of power towing my 11,000# fifth wheel and otherwise no symptoms of problems at any time. Hopefully by tomorrow they will let me know. Off the record, any idea what the injector harness costs for the back 3 cylinders and how hard is it to change?

Thanks for the advice so far....Don

 

The injector harness for the 06 and 07 model year CTD's is integrated into the valve cover gasket. This is the complete harness unlike the 03 to 05, where the harness is three separate parts. I have attached a link for the valve cover gasket with harness. The cost is 100.85. I am sure that the dealer cost will be a smidgeon more.

http://hoeslidiesel.com/store/page13.html

 

OK, injector valve cover wiring harness changed, injectors ohms check OK, and no improvement. Mechanic is still leaning towards injector problem. Any thoughts from outside? 2 weeks this coming Friday and no consistency

He changed all above then drove truck after warming it up. Ran perfect for 1/2 hour but when he hit full throttle check engine light and same codes. Truck appears to be running on maybe 3 cylinders when check engine light comes on, barely enough umph to pull away from a stop sign, It will get to 50 mph or so but very difficult to do so. He is going to run the other connecting wiring harness for a short and then start on injector checks. Being a Dodge dealer not sure of what kind of testing he can do on injectors but am hopeful something will show up......

 

Dealer changed wiring harness, new code then pointed to #5 injector. Replaced same truck now runs excellent. Just got home with it, Hammered it any way I could and zero problems. Mechanic left new harness on truck as he thought it contributed to the problem and told me it was the electronics in the injector that failed not the tip so he could not find a reason to put the old harness back on although his service mgr wanted him to do so. When I asked he told me that the truck was shifting into limp mode as it saw a problem and cut everything down to stop damage (?) not sure I said it right but hopefully you get what I meant. He appeared to have put over 60 miles as I told him to drive it to make sure there were no further problems. Not sure Chrysler will foot another bill with being out of warranty for sure now as I was 4 week out of warranty for this repair but only at 55K miles.

At any rate greatly appreciate all the assistance and comments, just hope my Cummins jinx leaves me on this one. Chrysler for once did me OK on this one, think dealership made a few extra dollars but even at $250 my cost, think I did OK. New injector harness/valve cover gasket, (Dodge price $300, Cummins $106) new injector, high performance "stock" air filter ($35), and CRC injector cleaner installed ($20). Truck runs like new and is quieter than it has been for a while so I'll go with it and hopefully not look back.


thanks again.....Don