no oil pressure
A timing chain cover isn't under a lot of pressure other than what ever air pressure is in the crankcase. So for the chain cover to leak on a new rebuild tells me the rebuilder didn't seal at least that part of the engine properly. If there is a lot of pressure in the crankcase then it could be that the PCV or other breather isn't working properly or the rings are leaking badly.
I have never heard of punching the relief valve, a weird problem and strange solution. But anyway, not having pressure when you put on a new filter and then getting pressure after punching or disabling the relief valve tells me the oil pump system is too weak to push oil thru the filter. Not good. Do you have a mechanical guage? A lot of the newer trucks have dummy guages that read right about normal almost no matter what until the engine siezes.
Wild guessing on low oil pressure is the relief spring in the oil pump is dead, there are some massive oil leaks inside the engine due to improper assembly or maybe a gasket was put in wrong and cut off the oil flow.
With a mechanical guage you should be able to tell what your actual pressure is. I would start with knowing what the pressure is. If it is low, you would need to look for bad pump, clogged or plugged passages, loose bearings, missing oil gallery plugs etc.
You said external oil filter. Do you mean a remotely mounted versus engine mounted filter? If remote, are your oil lines clear and not twisted etc? Can you check if oil goes into and out of the mount easily?
With 10,000 miles on the engine, maybe you are still under warranty?
Good Luck,
Jim Henderson
Thanks, Allen






