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Technical Info: 3rd Generation: DRIVETRAIN Technical discussion of third generation (2003 - 2007) engine and drivetrain questions, solutions and upgrades.
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Old 10-15-2019
RamDiesel3500's Avatar
RamDiesel3500 RamDiesel3500 is offline
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Default Injector swap

After 16 years and 372K miles, my truck finally became very difficult to start. I suspected the ball seats in my injectors were leaking as this has been noted as a very common problem with trucks of my vintage. So, I shopped around. My budget being small, I decided to give Pensacola Diesel a try as they offer a really competitive price on a complete replacement kit. The kit came with 6 remanufactured injectors, 6 new feed tubes, and all the necessary top end gaskets and O-rings as well as instructions and a bottle of fuel treatment. I installed the kit complete being very careful to follow instructions and torque values. Fired up the truck and after a short time of sputtering it smoothed out and ran very nice. However, after approx. 200 miles of driving, my crankcase managed to grow about 1.5 quarts of oil...or should I say diesel fuel/oil mix. So, I pulled the top back off the valve train. Fired up the engine and watched....nothing. Then, I pulled the plug on the FCA. Bam...diesel fuel spraying and fogging out of the side of #4 injector. It had a split in the side of the upper cap body (probably not the correct name for that part). Pulled that injector and called PD. They immediately sent out a new injector. When it arrived it, like previously for the six cores, had a prepaid shipping label for me to send back the defective one. I installed the new injector, changed the engine oil, fired up the engine, no apparent leaks even at high pressure, and it ran perfect like before. So, if anything changes I'll post, but for now I am cautiously optimistic that all is well. Even with lost time and the extra oil changes, I still feel like I got a good deal for the money spent. Lucky for me that I did not need the truck badly while it was down for repairs. (good weather and a super glide made that possible) I will probably check my oil a hundred times over the next couple of weeks!
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2003 3500 ST 4x4 QC SWB SRW Black 305/555 ISB NV5600 3.73LS Tow Pkg, Tow Mirrors, Z-liner. Added Factory Cruise Control for $43.00** Silencer Ring & Baffle tube on shelf in garage. B&W hitch.* 372K on odo.* Magnaflow 4" Stainless Turbo Back - Vrooommm!!* REAL TRUCKS DON'T HAVE SPARK PLUGS OR GLOW PLUGS!!!* God Bless
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Old 10-15-2019
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Thanks for the info and update. Glad it 's working for you.
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01.5,Red QC Sport SWB,HO,6spd,4x4,cowl hood, Drag Comp,4"ex., fuel press. gauge, boost&pyro gauges, bhaf, single Holley lift pump next to the fuel tank/13psi WOT, Vulcan Big Line, cheapo fuel cooler, Amsoil in the trans. & Valvoline in the pan, 62-65-.70A/R, ARP studs, kevlar/ceramic SD clutch, jammer 100's

Time to turn so's you don't burn.

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Originally Posted by bigreddog View Post
if I get new gutters every year I never need to clean them
True love is when she gives you the ham from her egg mcmuffin
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Old 10-16-2019
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I've heard a lot of complaints about them over the years. Defective parts, bad workmanship, and the like. Maybe they are finally getting their act together.
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RIP 1991.5 1991.5- 8/14/2013
92 W250 Xcab 4X4, HD 47RH with Compushift, Scheid Lightning VE, GDS moded H1C/w 16cm, 7X010 DAP injectors, DE 4" exhaust, 60# valve springs, the usual gauges.
01 2500 Q cab 4X4, stage II auto, fresh VP-44, HX35, B T E and F gauges, FASS 95 adjustable.
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Old 10-17-2019
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Good deal!
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2003 QC HO 6SPD, 305/555, 4WD, TST Controller W/monitor, fuel pressure guage, 100% Amsoil

sold
'96 2500SLT CC LB 2WD, KDP tabbed,100Hp Maxsticks,16* ,3k gsk,afc modded,#8 tst plate,62/70/13 turbo,4" MBRP exhaust,AFE stage III dry filter intake,autometer boost pyro, oil, tran temp,DSS,rebuilt diff & tranny w/billet triple lock TC w/lockup switch,1tn rear cylinders,ride rites on all 4 corners w/on board air,465k km. 330 hp 766 ft/lbs
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Old 10-17-2019
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Good to see you Chris!
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01.5,Red QC Sport SWB,HO,6spd,4x4,cowl hood, Drag Comp,4"ex., fuel press. gauge, boost&pyro gauges, bhaf, single Holley lift pump next to the fuel tank/13psi WOT, Vulcan Big Line, cheapo fuel cooler, Amsoil in the trans. & Valvoline in the pan, 62-65-.70A/R, ARP studs, kevlar/ceramic SD clutch, jammer 100's

Time to turn so's you don't burn.

Quote:
Originally Posted by bigreddog View Post
if I get new gutters every year I never need to clean them
True love is when she gives you the ham from her egg mcmuffin
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  #6  
Old 10-18-2019
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Update: I am happy to say that after 300 miles of driving after replacement of the bad #4 injector, the oil level in the crankcase has not moved! The oil is so clean that it's very difficult to see on the stick. Guess I got a real good internal engine cleaning out of this or'deal as well! Truck runs great and starts very easy now. I probably don't need to carry my little Harbor Freight 2-stroke toy generator with me anymore on cold days. For the last several years that little genny made it possible for me to get home from work on a cold day by powering my block heater to keep the engine head warm which, in turn, made the injectors seal up good enough to allow me go build the necessary 4000psi during cranking so it would start.

Not a problem anymore!!! WooHoo!! This truck runs so nice now that I started wearing my Cummins hat again!!!
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2003 3500 ST 4x4 QC SWB SRW Black 305/555 ISB NV5600 3.73LS Tow Pkg, Tow Mirrors, Z-liner. Added Factory Cruise Control for $43.00** Silencer Ring & Baffle tube on shelf in garage. B&W hitch.* 372K on odo.* Magnaflow 4" Stainless Turbo Back - Vrooommm!!* REAL TRUCKS DON'T HAVE SPARK PLUGS OR GLOW PLUGS!!!* God Bless
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Old 10-18-2019
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Quote:
Originally Posted by RamDiesel3500 View Post
WooHoo!! This truck runs so nice now that I started wearing my Cummins hat again!!!
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01.5,Red QC Sport SWB,HO,6spd,4x4,cowl hood, Drag Comp,4"ex., fuel press. gauge, boost&pyro gauges, bhaf, single Holley lift pump next to the fuel tank/13psi WOT, Vulcan Big Line, cheapo fuel cooler, Amsoil in the trans. & Valvoline in the pan, 62-65-.70A/R, ARP studs, kevlar/ceramic SD clutch, jammer 100's

Time to turn so's you don't burn.

Quote:
Originally Posted by bigreddog View Post
if I get new gutters every year I never need to clean them
True love is when she gives you the ham from her egg mcmuffin
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Old 1 Day Ago
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RamDiesel3500 RamDiesel3500 is offline
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Nuther update! I've put about 3K miles on it now since the injector replacement (x2). Oil level is not moving, truck runs fantastic, and it starts immediately no matter how cold. I am happy happy happy.....so far anyway!
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2003 3500 ST 4x4 QC SWB SRW Black 305/555 ISB NV5600 3.73LS Tow Pkg, Tow Mirrors, Z-liner. Added Factory Cruise Control for $43.00** Silencer Ring & Baffle tube on shelf in garage. B&W hitch.* 372K on odo.* Magnaflow 4" Stainless Turbo Back - Vrooommm!!* REAL TRUCKS DON'T HAVE SPARK PLUGS OR GLOW PLUGS!!!* God Bless
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Old 8 Hours Ago
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Glad to hear I may be coming that way 188,000 truck still starts with grid heater runs and tows good BUT?
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2005 SLT 2500 3.73 Automatic, reg cab, spray in liner, stull runnin boards,12 volt winch power to bed, slide out loading ramp 4ft by 8ft.Bone stock silencer now MIA 95 gph fass adjustable pump and straw kit
06 dodge 1/2 ton 2wd gasser 4.7 l auto [replacement for giving the son the ford] went to my mother 2017 1500 5.7hemi 10,000 original miles

2014 Cadillac CTS 2.0 turbo
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