05 lower end knock

pcassidy111 · June 4, 2005

I have an 05 that, when idling warm, sounds like it has a lower end knock-a dull thud. Crawled around under the truck listening to the pan, block, trans etc with a screwdriver but could not pinpoint it. Did notice that the combustion noise (the ticking noise) cycled with the knock. Is this a normal noise? How do you guys find noisy rods, lifter etc, these engines are a symphony of noises.

While under the truck I did notice a few drips of black oil on the bottom of the bellhousing. It came from the inside, hit the top of the rubber plug and exited the bellhousing. Could it be assembly lube, my oil is still a golden color. I looked in the gallery of leaks and did see the dark material on the crankshaft of mine, but the top and sides of the bellhousing plug were also wet. Do they put dye in the oil at the factory? The oil does not have the tint to it that the oil dye I use gives the oil.

Also noticed that the output shaft seal on the transfer case let go and the transfer case is nearly empty (according to the dipstick that I made). Think they will give me a new transfer case?

This truck only has 1100 miles on it! Any information would be greatly appreciated, I work at an independant shop and we have not seen many of these motors yet (most of our commercial accounts still use gas motors.

Keith Browning · June 4, 2005

Pete,

They are noisy engines and if you had a bottom end knock you would know it, particularly off of idle. I take it this is your truck? This will be a good learning experience for you before you start to see any customer's trucks.

1100 mile's and leaking already?! Here's what you want to remember. Rear main seals generally, do not leak on this engine and should not be your first suspect. Common stuff I have been seeing is camshaft and crankshaft sensors seeping oil which runs back along the bed plate seam to the bell housing. On top of the engine I have seen loose CAC hoses leaking collected vapors that seep back across the top of the engine and down either side of the rear of the engine. Glow plug buss bars and connectors also have become a common source of oil leaks down the back of the engine as well. Look for connectors not fully seated in the cylinder head or leaking through the wiring in the center of the connector. There are MANY things that can leak and we all have some great horror stories to tell but these are the most common items to look at first.

Any other leaks you will need to use dye. I think "they" stopped putting dye in new engines back in the 7.3 days. You will need to use one bottle of dye for every 5 quarts of engine oil. I have found that filthy engine oil drastically reduces the dye's effectiveness and sometimes changing the oil is necessary. I doubt you have warranty authorization like some of our city and fleet members here do. I would definitely poke around and get some hands on, then get it to the dealer to warranty the leaks, especially the transfer case before you damage it.

Many of these engines are soon to be coming out of warranty so you are going to start having some real fun when you start to see them. /forums/images/%%GRAEMLIN_URL%%/rofl.gif (sorry, I couldn't help myself)

pcassidy111 · June 4, 2005

Thanks for the info. Just towed it to the dealer for the transfer case leak and I will add some dye to the oil and try to find a leak and then send it in for a warranty repair if necessary.

Looked at the pictures of oil leaks and I did see the assy lube on my crank. The rubber plug below the crank was wet on top and with a mirror I saw no oil in the bottom of the bell housing. The substance was black and my oil is still honey colored so I am hoping that it is excessive assy lube (wishful thinking?)

Regarding the 6.0L coming out of warranty I am gathering as much info as I can from this site regarding R&R etc. I thought pulling a 5.4L in a pickup was a pain (until my dealer friend told me about lifting the cab), doing a 6.0 does not look like fun at all-you dealer guys really earn your money on these. Why can't they be like the old VW bugs, 4 bolts, a couple of wires and a fuel line and it is out?

Thanks again for the info, Pete

Jim Warman · June 4, 2005

Pete, I always seem to go back to my trusty old ways (or is that CRUSTY old ways??)... A length of vacuum of fuel hose (be sure to stick the clean end in your ear) and even me with my tinitis can localize sounds.

One of our pups had a noisey one not that long ago... After a couple of days of swapping flywheels and checking cam drive keys, we started the motor sans transmission. The noise was loudest inside the pilot bearing.

Further investigation revealed one pooched rod bearing and it's mate with tattletales indicating a bent rod.

Watch the old guys.... diodes and modules can make us scratch our heads, but there's more old school tricks than you can shake a stick at.

pcassidy111 · June 4, 2005

As you can probably tell, this is the first diesel that I have owned so I am somewhat parnoid when I hear noises that sound like a problem in a gas engine. I came across some information on the International Engine web site that talked about 'cackle'. It describes what I am hearing, an intermittent rod knock like noise that is loudest at the driver's side rear of the engine at warm idle, that goes away off idle. Can't determine the date of this information-do you folks working on the 05 motors hear the cackle or is this old information? Thanks to Jim and the Diesel Doctor for your replies on this subject.

Keith Browning · June 5, 2005

The infamous "cackle" noise was a characteristic of the 7.3L PSD. It was caused by the fuel pulses in the fuel rail on the left cylinder head causing problems with the number 8 injector. The fix was a "special" injector made to be installed in cylinder #8. In some cases it was quite loud on some vehicles and you would swear something was coming apart.

You described the sound of these engines as "a symphony of noises." I love that. If you just lean against the fender of a running truck with the hood open and spend a few minutes just listening you will start to pick out several sounds. I know it sounds like a strange thing to be doing but I have done it. Fortunately none of my co-workers have caught me or so I believe - I had my eyes closed while I was doing it. /forums/images/%%GRAEMLIN_URL%%/laugh.gif

Jim Warman · June 5, 2005

Like Kieth, I listen closely to everything the motor is trying to tell me..... he can probably hear it much better than my battered old lug-holes...

Sorry I can't tell you what sounds are distressing and what sounds aren't.... The feeling comes with time and experience, I suppose (but I can't prove it)... you will, however, get to the point where some things just sound "right" and some don't. I still get the odd truck that don't sound "right".... but it don't sound "wrong" either.