Pulled the engine out of my 03 beause of a constant knock. Thought I had a bad wrist pin on numbers 6 due to faint noise when moving drivetrain. Pulled #6 and found the skirt and cylinder to be scored on one side. I thought maybe a hone. Builder says whole engine needs rebuilt. (note: he is basing this on seeing the piston only) He also says that the rings are worn terribly. The gap looks to be about 5/16th of an inch. He says I HAVE to pull crank and rebore.
Now here is my dilema...I work construction and have been off for 2 weeks and have nothing lined up in the near future due to this economy. Therefore...even though everyone says full rebuild...I have no problem fixing what needs fixed then in a year or so goin back through it. My labor is nothing...It's the build bill I fear.
So... Does the crank HAVE to be pulled to bore the cylinders ? My rod bearings all seem good. The scoring seems due to lack of oil on the #6.
Also...Is there ANY place to get the engine parts besides Cummins ?? He says that we should be able to get just as good aftermarket parts alot cheaper. However he called 2 companies while I was there and they both told him that they could only get parts up to 2002.
Another thing I knew the rings were a little bad due to the exhaust haze at idle even with the computer off, but the way he is talkin they are really bad. If they have been this bad all the time I have had it...I can't imagin how much power this thing would have fresh

 

I just don't get it. I have spent hours looking online for a simple rebuild kit for an 03 and can't find ANYTHING with a price. I go to Cummins.com and I may as well be bouncing my head against the wall. What is the secret ?? My local Cummins Dealer is not much help. He acts as though since I don't roll 18 wheels that I am wasting his time.
Just trying to see what this thing is gonna cost me and can't even get a ballpark price.

 

http://www.btmccorp.com/heavyduty/cu...FQQilwod9X3UwA

Go here... your engine is either the 6BT 5.9L (std.) or the 6BTA 5.9L (HO)... '03 had either option...

 

did a quick search online and got these, hope these will help....


http://www.agkits.com/index.asp?Page...OD&ProdID=1712

http://www.btmccorp.com/heavyduty/cu...FQUQlwodthFdxA

http://www.rpmrons.com/Chry,kits.html

 

Thank you both so much. I did not realize that the 6BTA was the same as the 03 24 valve HO. I can put some of my hair back in now as I check these sites out.

 

If you are going to have the motor bored, more than likely a steel sleeve is going to be installed, bore the block, press the sleeve in, then hone it to the new piston, so yes the crank will be removed, but so will the engine from the truck. Maybe you can get away with a rering job if you want to say money. All depends on what the block/pistons are like.

 

man all these problems with engine failure makes me want to go back to my 2002. I have all ready went through 1, a buddy of mine has went through 2, and even another guy arounder here has went through 4.

 

Checkmate,
To answer your question your engine can be honed with the crank in the block. It really depends on how bad it is though. If you need a hand on the rebuild and you can get the engine over here to my shop I would gladly DONATE my time and shop to help ya out.
Give me a call.
Topper

 

In defense of Cummins, I am in no way blaming a bad engine on MY case. I was due for an oil change, my filter had vibrated loose and dumped out 6 qts of oil (could have been low for a week), and I ran it for at least 5 miles close to 3,000 rpm. with the quad set on 100hp. Then after i developed the knock i put another 3,000 miles on it and the knock never got worse (by ear). At just over 200,000 miles I would not and should not expect the engine to have not been harmed in some way.

 

Topper, I really appreciate the offer and it's definately tempting, i'll have to get back to ya in a month or so and see if your not too busy then.

I am going to check the cylinders later today. I personally think I can get away with a hone and new rings. What is "allowable" as far as cylinder out of round ? Obviously I don't want to just hone it and ring it and end up worse.
Thanks, Dan

 

WHY ARE YOU RUNNING TWO THREADS ON SAME SUBJECT! HOPING FOR CONFLICTING SUGGESTIONS? This answer will be for both threads.

If only # 6 piston/cyl wall is scored bad enough to require boring, and the rest are still standard, you could have that hole resleeved to standard and just do a rering job on rest of engine. Problem is finding some old school machinest that can do the job.
Another alternative is bore that cyl OS and use OS piston on that cyl. It will work. Also from ring end gap you mentioned, rings are worn out. I have seen instances of removing the al galled to cyl wall with a acid and have a acceptable bore after. Just need a new piston and rings. O'K maybe it will knock a little, but if can't aford the whole job, it is a alternative. Measure wear and out of round.

 

6Bt's aren't sleeved are they? I wish they were.

Nick

 

The subject on the other one is a question about a wrist pin. This was more in regards to info wanted for a rebuild. I figured possibly that I might not get some of the guys with answers would not re visit the same thread if thy already answered the subjects question. I was hoping the other thread would die. BTW Thanks For The Thread Bump On That Other Thread !!! Just jokin.

I really do appreciate all the knowledge I have gotten from this site and the people on it. When it comes to Dodge and Cummins I respect the opinions I get on here more than that of my engine builder because he is not up on the new diesel engines. So..when he gives me HIS opinion, I get on here and weigh it against the opinions of the guys who seem moreso to know what they are talking about.
Thanks, guys

 

Does anyone know if a company named Molley (sp?) makes the pistons for Cummins ? My engine builder says they do and he can get them alot cheaper than from Cummins. I told him I was skeptical.

 

Well I did a search and it took a lil while since I had the spelling off.
The pistons are Mahle and it looks like from what I found that these are the pistons that Cummins started using in 2002. So apparently my guy can get them cheaper than goin through Cummins. Maybe I can nickel and dime my way out of a huge bill. :-)