Cummins ISX head gasket problem - TheDieselGarage.com
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post #1 of 16 (permalink) Old 12-03-2011, 03:48 AM Thread Starter
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Question Cummins ISX head gasket problem

Has anybody experienced a blown head gasket on a Cummins ISX engine, only to find that some of the cyl. liners had sunk in the block?
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post #2 of 16 (permalink) Old 12-04-2011, 08:34 AM
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Yup. Seen five or six. All low k (400,000 or less). All under warranty, usually number five or so that is too low. Cummmins does not yet have a block cutting tool like cat, so you have to replace the whole block.
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post #3 of 16 (permalink) Old 12-04-2011, 03:52 PM
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Originally Posted by pushbroom View Post
Yup. Seen five or six. All low k (400,000 or less). All under warranty, usually number five or so that is too low. Cummmins does not yet have a block cutting tool like cat, so you have to replace the whole block.
Wow thats terrible!
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post #4 of 16 (permalink) Old 12-04-2011, 10:11 PM Thread Starter
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Money saving solution

I posted this question to see how prevelent the problem is. I have heard of at least 52 case of this problem. Some were high mileage, and some were not high mileage. The latest one that I heard of is a 2010 with 300,000 miles on it. Since this owner operator did not purchase the extended warranty, Cummins will not help him out at all. Many that I heard of, (from the Cummins service rep), were 2007 trucks with extended warranty, and Cummins replaced the blocks or engines, because Cummins has no repair for it. My job is to do in-frame machining on diesel engine blocks so I was asked to machine the counterbores on a ISX engine for shims. I searched and searched for the tooling & shims for an ISX, with no success. Cummins says that they may have something available by the beginning of next year, but they did not seem to sure that it would happen that soon. So I developed a machine to cut the counterbores in-frame, & I had stainless steel shims made in .018" & .041" thick to allow me to repair these blocks. I think that reason these liners are sinking in the block, is because Cummins is setting the liners too low, (.007"-.009") which is allowing the liner to squirm in the block, thus wearing the counterbore away. I can now machine these blocks in-frame for shims, which allows me to bring the liner protrusion up to .014" which holds it much tighter. (The spec. is .007-.014") This adds a dissimilar metal (SS) between the cast iron block & the cast iron liner which reduces wear. This is not my business, just my job. My goal is to try to save truckers money, whenever I can so I developed this procedure to save them from having to remove the block from the truck & replacing it with a VERY VERY expensive new block, not counting the downtime it would cause.
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post #5 of 16 (permalink) Old 12-05-2011, 01:02 AM
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We have done six at our shop, but I have heard of about 15 more cases that happened locally. Cummins told us the same, that they are working on tooling. I imagine by the time the tooling is available, the majority of the blocks would have been replaced. I am interested in the tooling you made up. Pics please??? Any chance of the tooling being made commercially?
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post #6 of 16 (permalink) Old 12-06-2011, 06:06 AM
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Originally Posted by Truck engine machinist View Post
I posted this question to see how prevelent the problem is. I have heard of at least 52 case of this problem. Some were high mileage, and some were not high mileage. The latest one that I heard of is a 2010 with 300,000 miles on it. Since this owner operator did not purchase the extended warranty, Cummins will not help him out at all. Many that I heard of, (from the Cummins service rep), were 2007 trucks with extended warranty, and Cummins replaced the blocks or engines, because Cummins has no repair for it. My job is to do in-frame machining on diesel engine blocks so I was asked to machine the counterbores on a ISX engine for shims. I searched and searched for the tooling & shims for an ISX, with no success. Cummins says that they may have something available by the beginning of next year, but they did not seem to sure that it would happen that soon. So I developed a machine to cut the counterbores in-frame, & I had stainless steel shims made in .018" & .041" thick to allow me to repair these blocks. I think that reason these liners are sinking in the block, is because Cummins is setting the liners too low, (.007"-.009") which is allowing the liner to squirm in the block, thus wearing the counterbore away. I can now machine these blocks in-frame for shims, which allows me to bring the liner protrusion up to .014" which holds it much tighter. (The spec. is .007-.014") This adds a dissimilar metal (SS) between the cast iron block & the cast iron liner which reduces wear. This is not my business, just my job. My goal is to try to save truckers money, whenever I can so I developed this procedure to save them from having to remove the block from the truck & replacing it with a VERY VERY expensive new block, not counting the downtime it would cause.
Where are you located?
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post #7 of 16 (permalink) Old 12-06-2011, 11:37 AM Thread Starter
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Smile My location

I am in southeaster PA, and am willing to travel anywhere to help out a trucker.

Last edited by Truck engine machinist; 12-06-2011 at 11:42 AM.
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post #8 of 16 (permalink) Old 12-06-2011, 11:42 PM
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Price on the tool? I am interested.

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post #9 of 16 (permalink) Old 12-06-2011, 11:50 PM Thread Starter
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The tool is not for sale, but I will travel anywhere in the world to repair blocks for anyone.
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post #10 of 16 (permalink) Old 12-09-2011, 02:32 AM
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Might there be a chance that you have a business card?, We have three isx engines in our fleet, they are all close to 1/2 million miles and at least one of them is starting to loose coolant.

We have done EGR coolers on all of them and I am keeping an eye on them, so just in case.

I can PM you the address to our shop, if you have a card (or could provide more info) we might be able to do some business in the future.
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counterbore, cummins isx, cyl. liner, head gasket

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