cbriggs Posted January 15, 2010 Share Posted January 15, 2010 Ive got an 08, 43,000kms. #1 piston cracked in half inline with the wrist pin. 0 psi compression. No other problems found other than missfire and blowby. Prior approval wants to know what caused piston to crack? Any ideas? I told them possibly injector failure, but no abnormal burn markings. No history of coolant loss or overheat or any work done other than a couple recalls. Quote Link to comment Share on other sites More sharing options...
Aaron Posted January 15, 2010 Share Posted January 15, 2010 Flaw In Material (D8 is the code, right?) No evidence of a hydro-lock on that one Chris? Coolant level ok before you tore it down? I was told typically when you get a coolant hydro lock from a blown EGR cooler on a 6.4, the engine favors #2 and #8 cylinders to fill with water first. Quote Link to comment Share on other sites More sharing options...
Alex Bruene Posted January 16, 2010 Share Posted January 16, 2010 Prior approval wants to know what caused piston to crack? Really? They must think you have some type of forensics experience. What are you doing wasting your time at a dealer? Quote Link to comment Share on other sites More sharing options...
joshbuys Posted January 16, 2010 Share Posted January 16, 2010 reply with F.O.R.D. Quote Link to comment Share on other sites More sharing options...
Aaron Posted January 16, 2010 Share Posted January 16, 2010 Fuggin' ol' rebuilt Dodge? Quote Link to comment Share on other sites More sharing options...
cbriggs Posted January 17, 2010 Author Share Posted January 17, 2010 Well, i replied that we suspected injector fault ( which is why i quoted it in prior approval). The prior approval estimate to repair (short block replace) was $13,400. The estimate to replace with new was $23,000 ish. We figured it was a no brainer so we pre ordered all the parts to do a short block, and hopefully get it out this week. Prior approval came back, approved, replace with new....... What? they oped for a repair cost of $10,000 more than necessary. Now we have a 6.4 short block in stock. Just when you think you have all this red tape b.s. figured out.... And for my own curiosity i stripped the piston out of the engine to see what is going on. Found that the injector had burnt a small hole in the piston (down thru the crown and out the side at the oil ring) and then it subsequently cracked. I will post pictures soon. Quote Link to comment Share on other sites More sharing options...
rlchv70 Posted January 19, 2010 Share Posted January 19, 2010 I think you have it backwards. Likely, the piston cracked first, then melted the piston. Quote Link to comment Share on other sites More sharing options...
cbriggs Posted January 20, 2010 Author Share Posted January 20, 2010 There's a couple pictures of the piston in photo post, cant figure out how to put them on here. Take a look and tell me your opinions on the failure? Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted January 20, 2010 Share Posted January 20, 2010 Allow me. Quote Link to comment Share on other sites More sharing options...
cbriggs Posted January 21, 2010 Author Share Posted January 21, 2010 Why thank you sir. Quote Link to comment Share on other sites More sharing options...
rlchv70 Posted January 21, 2010 Share Posted January 21, 2010 You can see erosion of the bowl at the ~8o-clock position. However, the photo gets cut off at 12 o-clock. What's it look like there? If it is eroded there, then, I would guess that the crack actually initiated there. Quote Link to comment Share on other sites More sharing options...
jimmy57 Posted January 21, 2010 Share Posted January 21, 2010 In my days working for a manufacturer there were some things I found out about warranty. The contract for components is not the same terms with every supplier. The manufacturer can negotiate price with warranty reimbursement as one item that can affect price. That truck's milage may have placed it in the situation where Ford gets reimbursed for a new engine but does not get full repayment for reman engine. I recall several cases where a FAR cheaper repair could be made by repair of a component but for that particular component the supplier paid for part but not for repair of that part so the A/C compressor got replaced instead of replacing the o ring seal at high pressure cutou switch.... Then there is the whole issue of some items going on full replacement for temporary engineering investigations. These are fun because about the time you think you may know what to do the rules change back! Quote Link to comment Share on other sites More sharing options...
LARRY BRUDZYNSKI Posted January 22, 2010 Share Posted January 22, 2010 Do you have any pic's from the bottom of the piston? Where does the piston cooling nozzle spray the underside? Quote Link to comment Share on other sites More sharing options...
cbriggs Posted January 22, 2010 Author Share Posted January 22, 2010 Bottom of piston looked perfect, from underneath would never know anythings wrong, i believe piston cooling jet hits opposite the hole. Thats not erosion at 8 oclock, just some shit on the piston, i didnt get too carried away cleaning, by this point i knew i was getting a complete, just satisfying my curiousity. Other than the crack and the burn hole piton looked fine. Quote Link to comment Share on other sites More sharing options...
cbriggs Posted January 22, 2010 Author Share Posted January 22, 2010 Oh yeah, claim got kicked back today. Apparently our repair was 790% above the national average? wtf. Does everybody else do them for free? The only thing i can think of is the causal part being 9e527? Going to change it to complete engine pn (6007?) tommorow and see what happens. Quote Link to comment Share on other sites More sharing options...
LARRY BRUDZYNSKI Posted January 22, 2010 Share Posted January 22, 2010 Sounds like a good time to move over to the WARRANTY thread. Quote Link to comment Share on other sites More sharing options...
joshbuys Posted January 22, 2010 Share Posted January 22, 2010 that is the problem with ford's system, dealers causing an engine failure against the engine rather than the actual causal - the injector in this case. it should give an option to continue with submission. everything we submit gives us the warning that we're some atrocaious % over the national average, my sm got a letter from ford a week or two ago saying we were getting alot of returns, but our fse and warranty auditor are telling us to keep doing what we're doing, the problem won't fix itself, if everyone would submit causal against ACTUAL causal, we could all be in better shape! Quote Link to comment Share on other sites More sharing options...
rlchv70 Posted January 22, 2010 Share Posted January 22, 2010 Bottom of piston looked perfect, from underneath would never know anythings wrong, i believe piston cooling jet hits opposite the hole. Thats not erosion at 8 oclock, just some shit on the piston, i didnt get too carried away cleaning, by this point i knew i was getting a complete, just satisfying my curiousity. Other than the crack and the burn hole piton looked fine. Picture looks eroded. If it's not eroded: Any possibility the truck was chipped? Quote Link to comment Share on other sites More sharing options...
cbriggs Posted January 23, 2010 Author Share Posted January 23, 2010 No sign of chip. Did have a bd cold air scoop on the rh fender that was plumed to air filter, but stock air filter and box. This thing ate alot of its oil before it came in, the turbos and intake were all full of oil, lots of gunk and carbon buildup on all engine parts. ( that may be why it looks eroded) i will get some more pics uploaded, but i can be certain there was no erosion on the piston. I will see if i have a pic after i wiped it down. Quote Link to comment Share on other sites More sharing options...
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