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This is a 2011 F250 6.2L with less than 80k miles.
Started as an occasional rough idle and some Cam Shaft sensor codes that would appear when warmed up. Went on for about a week.
Turned into a loud metallic knock that matched RPM. Only ran at idle and in/out of garage while knocking. Strange, but I had this same knock happen after replacement of exhaust manifold on opposite side of engine (drivers) about ~500 miles ago. That time knock persisted until warm then went away. Assumed a temporary blocked oil passage. Not the case this time.
By sound, tracked to passenger side and pulled plugs. Found this gem in cylinder #4, passenger firewall.
Briefly tried shopvac, air, and a magnet and doesnt seem to move. Likely welded into top of piston.
Valve spring and or rocker failure is a reported issue with the 6.2L. My assumption is failing Rocker or spring was causing intermittent idle issues, finally failed enough to drop some good stuff into the cylinder.
I was hoping to get some advice on next steps. Considering the damage, is it worth pulling valve cover, repairing spring and/or rocker if needed?
This is a backup truck so downtime isnt a concern, but also its not a truck worth throwing significantly more money into. Pulling the head is an option, but would like to avoid.
If that top photo is of a valve it looks bent or just not closing. The only way to know for sure is remove the valve cover but with the look of the cylinder wall I would say the motor is toast. It doesn't look like valve debris so I would say something got in there through the intake valve. If it dropped a valve or a piston contacted a valve you would hear it and see the marks on the piston.
Denny
You're right, ill be taking the valve cover off shortly to see whats up.
Anything in particular on the cylinder wall you see? To be honest I thought it didn't look too bad considering. No crosshatch, but my other healthy cylinder walls looked similar.
It looks scratched up from whatever is in there. I've seen cylinder walls that looked way better than that with over 100K on the clock. Only a compression test would tell if it's damaged or not.
Denny
Compression test for sure. BUT, IMO if you are not committed to pulling the head and having it redone, then it's a moot point. If it were mine, I'll pull the eingine and rebuild it. There is more wrong than just what you are seeing.
pulling the VC won't show you what happened as the item went though the intake track, filter, manifold and past the valve imbedding into the piston, sadly the fix is a motor rebuild at this time.
If that top photo is of a valve it looks bent or just not closing. The only way to know for sure is remove the valve cover but with the look of the cylinder wall I would say the motor is toast. It doesn't look like valve debris so I would say something got in there through the intake valve. If it dropped a valve or a piston contacted a valve you would hear it and see the marks on the piston.
Denny
good catch on the bent valve, now what flowed though the intake system imbedded into the piston scored the cylinder is a very big question, and a very pricy repair, junk yard motor or a rebuilt/rebuild
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