Keith Browning

I got my die-cast truck today and a debt card for the award ca$h. Is everybody okay? I know its Summer and all but it's quiet around here! Actually all the boards are a little slow. The second drawing is coming up!!!

I just finished up another one with one of "big brothers" weak points. An injector inlet o-ring failed stranding the customer with a couple tons of stone in the dump body. When I drove this truck it really performed well, you could feel the weight but the engine really got the truck moving. Braking and handling were not affected badly either. I rarely get to see these trucks loaded - just thought I would share my impressions.

Apparently there are more of these books than we are familiar with. We are trying to round them up and I will make them viewable to us in these forums.

I wonder if Ford will use the International kit and bulletin. I can see it now: R&R turbo -1.4, R&I turbo and recondition -1.6. At least Ford will save some money as cleaning will be far more cost effective than replacing all these turbos.

I believe the engine brake is "stock" and was there from the factory. I also had a similar situation with the control valve mounted on the engine.

Does anyone know if an ENGINE EXHAUST BRAKE is covered under the CAT warranty or FORD warranty? A customer had an actuator and valve assemble replaced because it was frozen. CAT charged him. This is a Jacob's engine brake in a Caterpillar box with a cat label and part number.

You cant accumulate many diesel engine diag operations when you are doing iron but that run seems to have ended... for now. (He knocks on wood) I finally got one more spin for $25! Thats $135 for 17 spins. Woo Hoo! Maybe I'll get lucky in the remaining drawings. I heard the average is $13 per spin. I guess I'm pullin the average down huh? My Rep told me that a lot of guys at some dealers are not using their spins. I don't get that at all unless the techs don't work there anymore and the dealer is using their certs for warranty?

Actually the Rooster came first. But thats another story. I really think that the head had a problem, the tech said he only found one of the valve keepers so who knows? Was it lost or was it never there? Look things over really well before you bolt them on.

Quote: Was this caused by debris left behind during the head gasket job, or by one of the new cyl. having a new valve that just decided to break off? Like the question of how many licks does it take to get to the center of a Tootsie Pop - the World may never know. /forums/images/%%GRAEMLIN_URL%%/smirk.gif I would say the head had a problem. The debris I had mentioned was from the broken valve pounding pieces of aluminum off of the piston and out into the manifolds where it made it's way into the other cylinders. That's my best guess on the chain of events. This truck is also suspected of being abused and is now on it's second engine. We are the second dealer to have the privilege of working on it.

Quote: Cummins Inc. has reached agreement with a major automotive manufacturer serving the North American market to produce and market a light-duty, diesel-powered engine. For competitive reasons, Cummins’ original equipment manufacturer partner in the venture has asked to remain confidential. Let us remember first that this stated "serving North American Market" could mean ANY manufacturer including Toyota. My guess is that Ford wanting to hang onto it's market, and Toyota looking to take over everything with predatory intent, my guess would be one of those two. Who ever breaks into the 1-ton market with a clean efficient diesel first will have an advantage. ON EDIT: As I was sautéing onions and mushrooms to go with my steak I could hear one of the Jeep commercials playing on the TV in the other room. Dr.Z was stating that they "would be introducing the Worlds cleanest diesel later this year." Well, Dodge IS already using Cummins engines...

You know what I am talking about? Ford Calls it the "Coffee Table Book" and others call it the "6.0L Bible" This is one of those absolutely awesome pieces of literature that is INTENDED for service technicians and service personnel. This kind of stuff rarely reaches us!!! I am really hoping that International and Ford puts out a similar publication for the 6.4L and actually GETS IT TO US! Please, if any of you corporate employees that have joined us here are paying attention would you kindly make a point of getting my request to the appropriate people at the appropriate manufacturer? I for one would be extremely grateful. One of the worst things I remember about the launch of the 6.0L is not knowing anything about the product and looking like a complete fool in the eyes of my customers when they ask questions.

We recently had an Excursion in with a really bad exhaust leak from the y-pipe which the customer let go for a long time. The oil fill cap looked just like the picture and some of the plastic conduit on the wiring was melted and brittle. Given that bit of evidence I might vote for heat as well.

As surprising as that statement might sound, 2010 is not that far away. I am happy to hear that "they" are thinking that far ahead. Nice to see you back - haven't seen you logged-in for a while!

WGLR13MWZ posted a snippet from an article in THIS POST and I know I read about this before. Just imagine the logistics not to mention the added cost of building an engine in Europe and shipping them to North America for assembly.

The kit was quietly but officially released on 7/17 by Ford and should be in stock. It was plentiful in the NY PDC when I ordered one for a customer. I don't know about the Interntional status. If you haven't seen it yet check out HPOP Connector Bracket . I was told that a TSB would be released for this part but I haven't seen one yet.

Got a camera?

Jim I guess those old eyes are sharper than you give them credit for? /forums/images/%%GRAEMLIN_URL%%/smirk.gif Makes you feel like a genius when you stumble onto something like this doesn't it?

Eric, sorry about the rant if I made you think is a nightmare. I was venting because I had a rough time on that last one and I used the e-mail address THEY sent me. It was different than the one I remember using in the past. All of my prior experiences with sending pics had gone smoothly. My only advice is to name the photos with either the VIN or the report number from the prior approval message - definitely put the report number in the subject line. That will help them find your message. Make sure the pics are CLEAR and in focus otherwise you are wasting their time and yours. Large file sizes are okay according to them so send your pics in hi resolution. Anybody else?

Is this a customer's truck or a personal truck?

Yeah Larry, the copper seal was there and there was only one. When I loosened the old down bolt it seemed to be properly/adequately torqued. I was more concerned about the upper bolt being loose and not fully seated and torqued down. It is fairly evident that the issue is not with the injector(s) as there have been three different ones installed in this cylinder. So my attention turns to the sleeve and the copper seal itself. I looked at the ring and it appeared not to be uniformly crushed and appeared to have been pushed off center. The hole in the middle where the injector tip goes through was oblong. I removed the sleeve and inspected it. No coolant leaks. No combustion leaks under the sleeve. No cracks and it did not appear burnt. What I cannot tell is if there is any variance in the thickness of the bottom where the copper seal mates with it. The marks left in the bottom of the seal also show that the copper seal had shifted. I can only assume that the sleeve was distorted - the head looked good and clean. I installed a new sleeve and sent the truck on it's way. Keeping my fingers crossed. /forums/images/%%GRAEMLIN_URL%%/frown.gif

I think that is true. I guess none of us are the winner of the first drawing. My own IDS would be nice to have but I am not sure what I would do with a Super Duty truck.

Yes, the bolt has a shoulder and it is supposed to be tight and locked before the injector and clamp are installed. I'm looking for a possible reason for these repeated failures. One note that does not support a typical loose injector failure is that the copper seal was not pounded away or burnt away.

One of our techs had sold a set of injectors to a customer with a high mileage engine that had gas run through the system. It originally came in running rough and smoking. The new injectors cured that. Since then, it has returned three times billowing white smoke and running poorly and would hydro-lock randomly. This being the "third try" the job is now mine. The previous failures indicated a poor seal at the base of the injector leaking combustion which in about 500 miles would burn away the lower fuel o-ring. By inspecting the copper seal I noticed that it was distorted like it was skewed off center and was slightly concave. It certainly was not sealing properly. I will be doing sleeves tomorrow. Okay, I'll get to the point... I also discovered the upper injector hold down bolt was loose. This bolt does not have to come out to replace injectors and I am unsure if the other tech had loosened it at some point. In your opinion is it possible for this bolt to loosen more if not initially torqued to spec? I removed it with two fingers with absolutely no resistance.

Interesting thread, looks like a tear down is necessary here. A sad note - one of my techs did a head gasket job a week ago and I believe both heads were replaced due to flatness concerns. Came back on a hook at the end of the week and he just got it torn down again. Cylinder #2 has an exhaust valve snapped off and embedded into the piston. My point is that the resulting debris actually traveled to the next two cylinders causing more damage. What looked like a problem with the entire bank actually can be pinpointed to one cylinder. Start diggin!

Oh I have the HotLine involved alright. I called them as part of the prior-approval process. They had gave me additional instructions to take pictures and e-mail them to an address they supplied. I spent 45 minutes making sure I got quality shots with as much detail as I could and then more time at home editing them and sending them off. I CC'd the e-mail to myself and received it immediately. I didn't hear back from them for a day until I called them. "We don't see your message here, could you re-send it?" Sure. I did so immediately. I called back two hours later - "no, they don't have it. Can I call you back at this number?" Call never came. Next day the approval showed up on the PTS site with a message about not having the photos and that an engineer might be calling. Maybe I should post it on this site and they can look at them in 350 X 262 resolution like everyone else! /forums/images/%%GRAEMLIN_URL%%/mad.gif Can you tell how pissed I am? I spent my own time on doing this for them and Ford's god-damn servers are so freaking wound up tight that my e-mails cant get through!!! Maybe Ford employees should start using Hot-Mail addresses. Don't get me wrong, I love being able to reciprocate in helping with the product but for cryin out loud, does everything have to be a challenge? /forums/images/%%GRAEMLIN_URL%%/shrug.gif