Cummins engine problem!

tinkerer wrote:
sounds to me they are trying to line their pockets. I have removed broken studs by welding a washer to the stud and then;) a nut to the washer and usually works better than you think. I thinking just heating the stud up helps free it. Also you only can do this with a Mig welder.

Every broken exhaust manifold bolt that I have seen on an ISL/ISC has been broken below the surface of the head. Also given that most coach arrangements do not allow a straight on view of the hole, I am not sure how you accomplish this?

jgolden wrote:
Did the shop have a theory on why the manifold leaked? Not sure what gauges you have but boost leak can cause high exhaust temps. Checking the Charge Air Cooler for leaks is a good idea. Mine had a few good sized leaks.
Haven't yet installed an Exhaust gas temp gauge or boost gauge but plan to. A stock engine should not over heat but age and wear and tear can "de-stock" one over time. Even a failed air filter can lead to shortage of air supply and high exhaust temps under high engine load.

Leaking manifold gaskets and to a lesser degree, broken bolts are fairly common on the ISC/ISL engines. Even with two piece manifolds, I see quite a few leaking exhaust manifolds. Usually repairing any broken bolts and installing new gaskets fixes them right up.

Cummins told me that number 1 and number 6 cylinders were leaking. They explained it as shrinking. On my engine the two part manifold is not available. I have 125,000 miles on the coach and she is 16 years old.
I know about CAC's replaced that two years ago and that was over $5,500. That included a rebuild on my radiator and oil cooler and all new hoses coolant, hydraulic fluid and air. Hope this year is less expensive.

This could be my last year to travel due to my wife health issues. I hope to get one more summer out of the heat.

Sorry signature did not append.
1997 Country Coach Allure 40'

Did the shop have a theory on why the manifold leaked? Not sure what gauges you have but boost leak can cause high exhaust temps. Checking the Charge Air Cooler for leaks is a good idea. Mine had a few good sized leaks.
Haven't yet installed an Exhaust gas temp gauge or boost gauge but plan to. A stock engine should not over heat but age and wear and tear can "de-stock" one over time. Even a failed air filter can lead to shortage of air supply and high exhaust temps under high engine load.

tinkerer wrote:
sounds to me they are trying to line their pockets. I have removed broken studs by welding a washer to the stud and then;) a nut to the washer and usually works better than you think. I thinking just heating the stud up helps free it. Also you only can do this with a Mig welder.

Its a Cummins shop, and if you saw the hourly rate, I'm sure you would say that they are trying to line their pockets. Thats just the way it is! I try to avoid those places. Lots of good Cummins mechanics out there, and they don't work in a Cummins shop! But the think is that lots of good mechanics do not like to work on Diesel Pushers. That is what sticks the feather in Cummins Coachcare's cap.

I had that problem last May in Coburg, OR. My engine is a 6CTA 325hp. Had a leaking exhaust manifold and the turbo was pushing oil. Cummins Coachcare in Coburg did the work. NO broken bolts. I soaked the manifold bolts with PB Blaster for three days prior to the removal. Total cost with a NEW turbo and manifold was $2500.00 and change. They did say if bolt are broken it would add labor, and could not estimate the cost.

Sure perked up the performance on my coach.

sounds to me they are trying to line their pockets. I have removed broken studs by welding a washer to the stud and then;) a nut to the washer and usually works better than you think. I thinking just heating the stud up helps free it. Also you only can do this with a Mig welder.

Snomas wrote:
The work is being done by Rocky Mountain Cummins in Denver, they said they soaked the bolts and several were already broken off which I could see (rusted) but I only had conversation on the problems w/ the head and the Turbo. Hope they were honest with me. They have been in the past.

That had to be pretty disappointing going in for something fairly that looked fairly minor and ending up spending $8000. Yikes!

I wouldn't automatically jump to the conclusion that you were taken advantage of. I have been in the middle of enoguh of these "Pandora's box" repairs to tell you that it does happen... more often that you think. And, I work in a fleet shop where there is no incentive to add on work.

As far as broken off bolts go, they are always a rescue mission. Anybody that tells you that they can POSITIVELY GUARANTY removing a broken exhaust bolt with the head in place is either superman or a complete fool.

The best way that I can think of to give yourself peace of mind is to have them show you the defective parts and explain why they felt that they needed to be replaced.

Good Luck!
Doug

The work is being done by Rocky Mountain Cummins in Denver, they said they soaked the bolts and several were already broken off which I could see (rusted) but I only had conversation on the problems w/ the head and the Turbo. Hope they were honest with me. They have been in the past.

ScottG wrote:
Cracked exhaust manifolds are common on those engines but turbos and heads aren't. I am very suspicious of their findings.
FWIW, even high EGT's will not damage a turbo, head or manifold. It takes out the pistons first and besides, a stock engine will not build that high of EGT's anyway.

Had several turbos on stock engines out out over the years.
Not unusual! These were on regional class 8 rigs.