Prevent Cummins Grid Heater Bolt Failure with Banks Monster-Ram

00:07 Is this start and run? It does start and run. I drove it to here. What’s And what’s the complaint? A uh loud ticking noise. What year is this? 21, I believe. 2021. Yep. Well, a loud ticking noise on a 67 fifth generation. What do you think it is? Yeah. Yep.

00:41 It does have a check engine light on. Also, you pulled the code yet? I haven’t yet. Why don’t you go grab your scanner? Let’s pull. Okay. Do you want me to shut it off? Uh, you know what? Let’s just pull it inside. It’s a little chilly out here.

00:53 Okay. And then, uh, I don’t even want to take it on a test drive. I mean, that doesn’t sound good. No, just rev it like that. Just like just for a second. Yeah, that you see. Did you Were you able to hear that change? What do you think that is? It sounds an awful lot like a a rod

01:17 knock, but it it does except when you rev it. Now, go rev it again and tell me and just hold it at about 1,500. Okay, let’s let’s do this. Let’s go ahead and pull it in. Pull the codes. Then we want

01:39 to pull the oil filter off of it and cut it open and have a look. Okay. Yes, sir. It’s obviously internal in the engine. You know, it’s either a lifter. Fifth generation 67 got uh roller cam shafts. Okay. They they got problems with them on. So, let’s uh let’s let’s pull the

01:58 oil filter kind of look, but let’s see what the codes are. Thank you. Okay. Yeah, that’s good. Let’s kind of Yeah. [Music] Yeah. It doesn’t smell overfueled. And he’s got oil levels in it. So, the oil is dark, but it looks it’s up. intake air heater and turbocharger boost. Neither of those

02:60 seem like an indication as to what the noise is. Mm. So, yeah, just uh document them, put them on the ticket. Let’s pull Let’s pull that oil filter off and have a look. Okay. [Music]

03:36 Now, what I’m going to tell you, what I like about this, you see this? You ever pan for oil? You ever pan for oil in in one of the rivers? Never panned for oil. I have, dude. For oil. Pan for gold. You ever pan for gold?

03:49 I have pan for gold. And you know how the pan’s got these little things in it? Yeah. To try to capture the little gold. Same thing here. We’re doing the same thing here. We’re going to try to We’re We’re panning for gold. Okay. Not paying for oil. Jeez, dude. And what do we have? Doesn’t look like

04:06 we have any, does it? No, it doesn’t. Nope. I don’t see any I don’t see any bearing matter in here. And I don’t see any of it. Mhm. What does that tell you? Probably don’t have Probably don’t have a rod bearing. Yeah. Yeah. And I didn’t think we did. You know, I think you got a lifter that’s

04:29 making noise on, you know, that’s failed. And there is an upgrade kit on this. We we changed this back to a flat tap at cam. It’s uh pretty pretty dang common on this motor. Anyway, but so what this tells us in my mind is uh we don’t really have to pull the engine. We

04:48 got to pull the head. It’s kind of a pain in the butt to do it in there, but you can you can change the lifters and and do this upgrade without pulling the whole motor. So, let’s go see what the guy wants to do.

04:58 Okay. The guy’s local. He is local in Yavin Logan, I believe. Okay. And did he give you any indication about how long that thing’s been making that noise? Just started, he said. Yeah. I thinking we got a a hydraulic

05:10 lifter that’s gone poo poo on us. It makes sense with the year. Yeah. But tell him the first thing we’re going to do tell him, you know, we already pulled the oil filter off. It’s all clean inside. I mean, it needs an oil change, but there’s no there’s no

05:22 rod bearing matter. But we’re going to pull the valve cover off first and we’re going to check and we’ll see cuz we’ll have a lifter, you know, a push rod that’s just flopping around in there. You got it.

05:41 You know, it does. It sounds healthy. This is not normally when these things start to tick. I mean, they’re it’s a it’s a pretty rattly tick. Mhm. Sometimes it’s intermittent when they’re not so bad, but you know, but this is a

05:53 this is pretty bad. So, pull off the valve cover first. Okay. And then come grab me. And uh I want to look and see if we’ve got, you know, you’ll know it cuz one of the rock arms will be flopping around. Okay. Okay. Okay. Okay. Cool. There we go.

06:38 Just stay there, Tyson. We’re looking for a lifter that’s not working. Ready? Go ahead. Hat. Heat. Now I’m a little worried that maybe and I didn’t ask the guy. Maybe the guy had the oil changed. It was pretty black though. But maybe he

07:39 had the oil changed just like recent before he brought it here. I’ll check it. And I’m And I’m looking at an oil filter that’s not that old because as bad as that was making noise, I would expect to see a rock arm that was hardly moving. Yeah. Go ahead and hook them up.

07:55 You got the key off. So listen for me to holler to shut it off. Okay. But go ahead and start it. Don’t rev it up. Just start it. I Oh, okay. It’s going to start. out here and get that back too. I don’t see those. They’re they’re working pretty good. I have the noise saying

08:52 well well how come we have no bearing matter in the oil filter is the question. I’m going to call the guy and find out how long that oil filter’s been on this engine because the only thing I could do is open that up and put it under my microscope and look at the thing. But I mean, as bad as

09:17 that is, dude, there’s got I’m I’m like, where’s the freaking where’s the bearing? Yeah. Unless I’m totally missing something here. See, I went down the rabbit hole thinking it was a cam cuz that oil filter is it’s clean as a whistle. Clean. Well, it’s got dirty oil in it, but it’s got no

09:34 uh metallic in it. Okay, let’s call the guy. We took his oil filter off, cut it open, didn’t find any metallic in it at all. Okay, I pulled the valve cover off. Okay, all the rockers are working correctly. And so, that tells me I don’t have a

09:51 lifter that’s collapsed or anything. So, it tells me he’s he he might have a bad rod bearing or something and it’s hitting that cuz it sounds like it’s in the head, but the piston the clearance he might be hitting the the head.

10:02 Okay. But my now my guess is that he just changed that oil filter before he brought it into us. Okay. And I and I need to know when was the oil changed on this truck and a new oil filter put on it. Call him. Let me know. Yeah. 2 hours later. Did you call the guy and ask him about

10:20 when he had the oil changed? about 3,000 mi ago. Oh my gosh. That doesn’t help me. That does not. So, that says it’s going to be something a little bit deeper. And as bad as it’s cranking, you’d think he’d have should be full of material. Material everywhere,

10:36 especially with 3,000 miles on it. Yeah. Well, how long did it knock on him? That’s maybe maybe we didn’t let it knock long enough. Wasn’t knocking long. It started knocking and he’s like, “Uh-oh.” Shut it down and trailered it.

10:49 He said it like that. I mean, as soon as he heard a knock, he shut it off. Got it back to the house and shut it off. Maybe that’s why I don’t have any in there because I mean, it’s, you know, that oil filter on first inspection didn’t have any matter in it. So, maybe he didn’t run it long enough. Be

11:06 interesting. But he’s motor’s going to have to come out and come down. So, but let me look at the oil filter. You got it. All right. I don’t see any metal in that at all.

11:25 It’s always nice when you have like, you know, it stands right out and hits you in the face. We’re going to pull the engine, man. All right, we pulled the valve cover off. We didn’t find anything wrong. No bent push rods. Couldn’t I mean, literally couldn’t find anything

11:37 going on inside there. So, we’ve talked to the customer, got permission. We’re going to pull the engine out, tear it down, and uh start looking. Find out what the heck is making that noise. [Music] [Music] [Music] [Music] [Music] [Music] Heat. Heat. [Music] [Music] Heat up here. [Music] Heat. Heat.

14:23 Yep, that’s me. You’re probably wondering how I ended up in this situation. Well, as you can see, that motor did tip over. Luckily, the only damage was the oil pan. So, all we got to do is supply a new oil pan. Everything else is great

14:37 on the motor. But, I did find the noise and the issue with this motor. It’s an interesting one. So, let’s go grab Miles and show them what we found. You might have found the noise. Yep. Um, so been tearing this down and went to move this harness. And if you notice, this started moving.

14:55 So that means our grid heater nut is likely going to be back in number six is my guess cuz it Oh my goodness. Yeah. So I’m just getting ready to pull this injector out cuz I want to bore scope it. I’m super curious. I can’t wait. Holy cow. Yeah.

15:16 Well, I can’t wait either, dude. So, let’s let’s tear it up. Yep. You know what? actually got one uh 10 to 12, something like that. Yeah. Yeah. I mean, it’s so that it’s plenty big enough to destroy an engine. That’s what moved

15:39 and it shouldn’t cuz that nut should be on the back side. Yeah. There she goes. Okay. Nothing looks like it’s contacted that injector. Look at the top of that pie. No, it does not. Looks like the crater of a moon.

16:11 Can you get down anymore? Yeah. So, this is why you do your grid heater upgrade with the Banks Ram intake. Oh, yeah. I mean, that Monster Ram is I don’t know why everybody doesn’t do it. Or you can end up like this guy. Hey, tap that round button at the

16:30 bottom. Take a picture. There you go. I’ll send that to you so you can A little longer than a few minutes later. So, we’re going to remove this head. But look at that. No nut. So, pretty sure that’s a culprit. We’re going to remove this head just to be as sure as we can. Okay. But that’s somewhere.

16:56 And I bore scoped the intake and it’s not in the intake, too. So, that’s okay. As he’s removing that, we checked the exhaust uh manifold. Nothing. Looking at the turbo, nothing. So, it’s either in that fifth or sixth cylinder or it disintegrated or something. [Music] Oh man,

17:38 look at that. Found number five. Look at that, dude. There it is. I wonder if something got into six, too. How does the back of the or the bottom of the head look? Oh, here I can Yeah. I’ll hold it right there. You see right there where the right there? Right there.

18:09 Man, just enough to make the noise. That almost looks like a bolt. Yeah, that’s probably what it is. What we’re seeing is the little bit of that stud there. Wherever the nut went. I don’t know, but that’s probably what we’re seeing is a little bit of that stud. Don’t you think? Yeah. I’m just

18:32 looking at all the other cylinders. Well, this is why you replace this dang thing cuz for a 10- cent nut, this customer is now having to rebuild their engine. Cumins owners, this is real. It does happen. Mhm. It’s not often, but it’s cheap insurance to just get rid of this.

19:08 Wow. Like, it’s It doesn’t move. Yeah. So, it looks like the the stud here got stuck between the intake valve on one of the strokes. You can see the intake valve um like compression mark on the

19:24 piston there. and then must have compressed once, bounced out, bounced over here, and then landed there. So, it did bend the valve. What are we looking at? Well, so just trying to find that nut. I’m going to show you. I haven’t found

19:38 the nut, but what I’m going to show you is what I found to see if you can help me identify some things. Let’s see. Right there in the bottom, right before the cat. Almost looks like gravel down there.

19:54 Now, I don’t know what that could be. I don’t think that’s pieces of a nut. Are you right up against this cat? Yep, I am. You can see the cat right there. Uhhuh. You just laying on the bottom. Yeah.

20:06 Yeah. Let’s take that band clamp off there real quick. Let’s just take the band clamp off and have a look. Let’s see if we can at least rotate it out of the way enough. Yeah, that’s that’s just this that’s the cat just coming apart. Yeah. I don’t see the nut though.

20:37 No. So, I didn’t see it there either. So, then I started working backwards and started went to look at the turbo. Yeah. You can see like right there. Oh yeah. See how this one’s all flat right here? Look how that one’s all bent and chewed up.

20:57 Look at that one’s all bent and chewed up. That one’s way whacked up. Yeah, something definitely went through this. Now the question is where did it go? Well, I don’t know. with heat and being pounded on it.

21:15 You You see how straight that is here? Let me show you this vein here. See how it’s missing a whole piece of it? I mean, I can get my there and then something there. It could have just chewed the dang thing up. I mean, these things spin, you know, at 100,000 RPM.

21:30 And uh it’s something’s definitely gone through it. But it sure would be nice to find more pieces of that uh nut. Let’s Let’s look to see. We got the stud in here. Yep. Stud’s there. But if you look at number six, it definitely had something go through number six.

21:51 You see how scored up the piston is? Yeah. It’s like, where did it go? Yeah. Okay. Well, make sure you add this to your things. He’s missing, you know, he’s he’s had teeth knocked off of this thing. Yep. I don’t know. We’re building uh a 2021, right? 67.

22:14 Yes, sir. Fifth gen. Fifth gen. What’s the problem with the fifth gen Cumins? Biggest problem is the roller lifters. You wouldn’t think it, but they do. They fail. And so, there is an upgrade kit. Um, in fact, you want to grab one of

22:26 those, Bobby, and let’s talk about that. Tell me, Bobby, why that thing looks so sweet? So, that’s a DLC coating, diamond light carbon. So, super thin, super hard coating that helps protects it against wear and tear that all engines see. It’s super nice. So, we we’re getting rid of

22:44 we they actually go back to this to the flat tap it and um so we get uh a rock arm assembly that’s adjustable. Yep. Goes back to the old style, the first through fourth generation, and it fixes

22:57 the problem. Uh I see we also got some coated main bearings in here, too. Yes, sir. And uh we doing anything anything special on the pistons? Our speed of air upgrade, the coating on top, the coating on the skirts of the

23:10 pistons. Well, we are. Let’s check it out. So, that’s the thing about today’s motors. There’s so many different type of coatings. So, we got a thermal barrel coating on the top of the speed of air piston. They put a dry film coating on

23:23 the skirt. You’re ready to build this thing? Yep. Yep. Crank’s about to go in and get the rods. Get the rods speced out. All right. All right. Well, let’s get on and do things. [Music] [Music] Heat. Heat. [Music] [Music] [Music] [Music] [Music] Goodness. [Music] [Music] Heat. Heat. [Music] [Music]

26:26 [Music] Heat. Heat. [Music] [Music] [Applause] [Music] Hey, [Applause] [Music] hey, hey. [Music] Okay, there slow [Music] one more. Okay. Oh like that. [Music] Sweet. Ken. So you ready to set the cab down this morning? I am. I am ready. It’s ready to go down.

28:18 It looks good. Yeah. Okay. So we got the intercooler tubes on. No intercooler. Banks is still in the process of doing that, right? Yep. The Fitch in intercooler isn’t released yet. Darn it. My truck’s a fit in. But it

28:31 looks like they size up quite a bit on the boost tubes. Yeah, it’s Yeah. I mean, leave Look at this hose here. That one replaces a plastic one that’s sitting right there on the ground. Plastic on a something with lots of

28:42 pressure doesn’t seem like a very good idea to me. Not long term. No. And then this side I love cuz this has some sharp bends. They mellow it out a lot. If you look, it’s more of a gradual.

28:54 Oh, yeah. So, that’s better for air flow. I haven’t noticed that. That is cool. Yeah. And then you got the thing that would have avoided his problem. This whole endeavor is if he would have had that. Yep. Now, this is the cool thing because Banks has the dual heater. Yeah.

29:12 And I think we’re the first ones to do it or you’re the first one to do it. So, this is the first one to be installed then. I mean, yeah. I think they might have test fit one, but we’re the first ones to do it. Cool. It’s It’s really slick. Yeah. The way they designed it.

29:29 So, why do you say that? What’s I mean, I know we have the dual heaters, but what’s it’s a little bit different than the one and I know we were talking about this the other day. They don’t have a billet cover anymore. It’s a cast.

29:41 Yeah. If you come over here and I can kind of show that a little more. So, this cover, it used to be billet with billet spacers right there, but now this is, as you can see, it’s all cast. So, right here for the fuel rail, that was a billet spacer before. So, it’s nice. It’s just all nice uh one

29:58 piece thing that just slides. Yeah. And I’m sure it also makes their manufacturing process easier for them, too. Yeah. Um, but and then on these grid heaters, so right here where you can see that plug. Yeah.

30:09 That’s where the one used to go, but you used to have to leave it out to get down there for one bolt. So now you can put the heaters in, leave that open, go in there, drop your bolt in, and then just put the plug in. Or if

30:21 you have to pull it off, you’re not having to worry about breaking the heaters. You’re just pulling that plug off. Interesting. That’s a cool upgrade cuz I mean aesthetically and if you just look at it real quick, it looks the same until you look over there.

30:33 Yeah, it’s really they just machined two extra little spots on the side. And everybody, this is not a paid advertisement by Banks. They have donated zero pennies to this video or anything. They just make good products. They did hook this customer up with this

30:52 new heater um because they heard about this issue. We called them the other day and said, “Hey, you guys won’t believe this. We actually have one of the nuts and studs that fell off and dropped into for sure cylinder 5, a little bit of six.” Well, what’s the next step? The

31:09 cab. Yep. Drop it down and prime the fuel system and it should be ready to start. Sweet. Okay. I can help you navigate this down. This is an exciting part of the process. I know. It’s It’s nice to put such a big piece back on. Uh-huh.

31:33 Okay. Good. If I keep coming down. Yeah. I’ll just watch the back here. Okay. I’m just going to go really slow. Four to six more inches and then roll the chassis forward and we’ll be we’ll be good. You want to put a block behind it? Yep. I think that’s about it. Okay, we’re like about to set down.

32:08 All right. Perfect. All right, the cab is back on. Kian’s going to hook up the rest of the hoses, wiring, and things like that to get this going. Then the next part of this is firing it up. So, we’ll get to it. Get this thing started. Moments later. Ready? Yes and no. This is This spot always

32:47 makes me nervous. No pressure. If it doesn’t start, you just got to pull it back off again, right? Yeah. All right. Okay. Well, go ahead. Okay. Stop. There we go. That’s better. Okay, just shut it off. We’ll let the batteries charge up a little bit. Yeah. Okay. And it kind of popped. So,

33:40 it’s got oil pressure. The next day runs great. Yeah, let’s take it for a drive. Dude, we uh we did some upgrades on this engine, didn’t we? Yep. It got uh quite a few different Banks things. So, obviously, it got the monster ramp. We got boost tubes on each side. Uhhuh.

34:08 Uh we got the Banks exhaust and we got the eye dash and pedal monster. Oh, yeah. So, it’s This thing ought to run like super sweet. Let’s go for a ride. It It runs good for sure. That pedal monster. That thing makes a truck. It’s amazing what that one item.

34:34 Oh yeah. Oh yeah. This thing is It’s like driving a sports car. We got our EGTs right here. Uh-huh. Which is the best insurance policy you can ever have on your diesel. Yeah. be able to monitor your exhaust gas temperatures in real time so that if

34:55 you have a any kind of fault where the engine’s, you know, going to melt the piston, you’ll know it. And I think if on like a This guy’s bulletproofs the crap out of this thing. This thing’s ready to go. All we need to do now is give it a nice

35:09 bath and deliver it to him. Yep. Excellent work, Gian. Thank you.