I'd be well into it by now if my cows could give me a break. Non stop problems - we had 2 dead cows and 2 dead calves yesterday, and had to electrolyte a bunch more... it's been 16 hour days and I'm too tired and grouchy to work on the truck. Maybe today or tonight.

 

Well, a month later, I finally got time to work on it. Got the motor out and passenger side head off. It's a mess. I have no idea what caused this, unless it was from the egr cooler failure years ago - it's had bad blowby for years, but always ran great. Not sure what I'm going to do, can these engines be sleeved? Number 3 is the worst, but 1,3 and 5 are all torched. This would make a nitrous pro mod racer envious.





#5

 

Here is #3 cylinder wall





All of the damage is in the same place, right at the exhaust valves

 

WOW!!! I sure hope you can get it fixed or another engine so you can stay in the family

 

Wow, that doesn't look good at all! Whatever would cause that?

Sent from Nexus 4. IB AutoGroup

 

No idea. The injectors were all good, even the ones I replaced a few years back were good, only suffering from cold stiction. I can't see how coolant could make a piston get so hot it melts. I have canned tunes on the truck, but all I ever use is the tow mode, that shouldn't put smiles on piston tops.
I'm searching for another engine, this thing is going to cost too much to fix I think.

 

I wonder if starting fluid could cause something like this? Have you ever had to use any?

 

Piston slap big time! No rings left on #3 it's been hot enough at some time to take the tension out of the rings and break them,but number 5 looks like a valve in the center of the piston.

 

John I am Sorry Maybe Venting the CCV to Atmosphere might have saved it

Hope this isn't to harsh But if it had Blowby since a EGR Cooler let go and popped the Head gasket then That would explain it

It was Only a matter of Time before the Truck run away from the CCV Tube

You was Dumping DIESEL FUEL mist Into Crank case with Blown Head Gasket,bad ring,valve train damage I suspect

Its self Inflicted from EGR Cool fail or whatever made Blowby but I suspect same as you

Your not the first melted piston
Bad Inject will melt piston too

But one the worst cylinder walls I have seen

What happen with the EGR Cooler
what extent was egr cooler damage???? Hydrolocked it?? did it let Loose on the Freeway??

 

The truck at Idle should have a Slight Vac at the Oil Filler Tube for you guys that are wondering about it

if it Blows out there then that's Too much Blowby or CCV Problem (CCV Might only apply to Modified CCV Systems God only knows how everyone did it LOL)

Don't 05+ Have a Box at the CCV/Intake outlet ????

 

Its odd that all the hot spots are all in the same spot on all the pistons.

 

Benny, I never even thought of that... of course... diesel fumes in the crankcase! I was thinking it was oil in the turbo, but your explanation makes more sense.
I don't think a head gasket let go, it certainly didn't have any symptoms of it. No coolant loss, no white residue etc. The egr cooler ruptured, I was a newbie, had no idea what it was, I had just joined here and started reading, I thought it was the ficm, so I drove it like that for a few months till it clicked that it was the egr cooler. It never went boom or anything, I just changed it and the oil cooler and carried on. Other than the blowby, it ran great, pulled like a champ.
As far as the CCV box, you need to look at my hemi powerstroke thread. It was hitting on the degas bracket when I was pulling the engine, so I took it off.
Shaneb... no I have never used starting fluid on it.
Got a line on a few engines around here, one is a 12 hour round trip, but it's been upgraded, and then the truck was totaled, it looks like my best bet.
I will continue to tear it down and post pics, I think I'll rebuild it this winter for a project, and have a spare or sell it.
There were lots of shiny flecks in the oil filter, not magnetic, but lots of them. Might be off the bearings, might just be the pistons shedding more debris.

 

well oil from a turbo would also do it

But yours Had that Blowby so I suspect HG,valve train, etc..

with a leaky egr cooler cylinder pressures could have gotten Higher then they should have

I wonder what the silver flakes are ffrom

 

It looks like an overfueling situation caused the gaulding of the pistons but from what I see of that cylinder wall, that's been going on for a while. Since there are 3 cylinders involved, I would usually suspect a tune that was a little too hot or a problem with the FICM. Since all three cylinders are on the same side, it may be a bad injector harness.
To answer your question about sleeving it, yes you can sleeve a 6.0 and you can bore .040 if that will clean up the other ones. As far as the metallic flakes in the oil, since it's not magnetic, aluminum from the pistons is the most likely, although it doesn't really matter at this point, it's toast.

 

Exhaust side heat is typical of a lean condition.... at least in a two stroke.
Over fueling would have acted like cooling I would think.

Injector harness, bad FICM or fuel pressure low would have made a lean condition.

OP never said he had a tuner..

Was a tuner used on the truck?