800hp 2006 5.9 Broken Rod Carnage - Competition Diesel.Com

Cflanery88 · 03-23-2017, 03:20 AM

Figured I'd post the results of a failed cyl#5 factory rod in my 2006. This occurred last June driving down the freeway cruise set at 70mph. Just now had the chance to pull the motor out and tear into it. Rod put nice sized inspection windows on both sides of the block, cracked the piston in half which also had a make out session with the valves, snapped the cam into four pieces, bent intake and exhaust extreme duty pushrods on cyl#5, created a two piece block stiffener, and cracks up both sides of the block about 2" from the deck surface which left the oil pan and remaining 2" of casting holding the back 2 cylinders on the block. Truck ran surprisingly until pulled to the side of the road and turned off with the key. Truck was very well taken care of, serviced every 2-3k miles with rotella T6 and zinc additive, daily driven and was pretty much stock except for the 2100 miles it was driven prior to the Rod letting go. One can speculate on what the cause was but I know for a fact it could have been prevented if I'd of invested in re-building the engine first, and building the bottom end to hold my power goals instead of on more air and fuel with aggressive tuning. I know, and have seen these live at a 1000hp with a stock bottom end but every block, service history, setup, and situation is different. Take my hard learned lesson and build the trans and motor first before dumping your money into a 800-1200hp ticking time bomb.

Signature shows hp/Tq and some of the mods at time of failure. I was running a ED billet 63mm over HT60 compounds. I Hope to have my new motor done within the next month or so with a better setup, and built bottom end to eliminate this issue going forward.

Thanks.
Pics to follow

Cflanery88 · 03-23-2017, 03:22 AM

Cflanery88 · 03-23-2017, 03:25 AM

Cflanery88 · 03-23-2017, 03:26 AM

Cflanery88 · 03-23-2017, 03:43 AM

Cflanery88 · 03-23-2017, 03:50 AM

Cflanery88 · 03-23-2017, 03:52 AM

Mooner1 · 03-23-2017, 06:57 AM

Man that sucks! Impressive carnage to say the least, crazy it was still running till you shut the key off. Glad to hear that you are on your way to getting re-powered with a 6.4 build though.

Cflanery88 · 03-23-2017, 07:11 AM

Thanks, yeah I was surprised too after looking at everything. Cylinder 5 bore didn't have any damage, all the crank journals were good, and the main/Rod bearings didn't show any abnormal wear. Hopefully the 6.4 build goes as planned and I don't run into to many issues along the way. Everything goes to the machine shop in a couple weeks hopefully.

Blueboy · 03-23-2017, 11:10 AM

Are you building new motor, or having it built ?

spooled05 · 03-23-2017, 12:22 PM

What was done to that engine in the past , that's not a stock 06 piston .

DodgeDude55 · 03-23-2017, 12:29 PM

Looks stock to me... just has a few kisses on it from the valves now

CorneliusRox · 03-23-2017, 12:54 PM

Quote:

Originally Posted by spooled05

What was done to that engine in the past , that's not a stock 06 piston .

Quote:

Originally Posted by DodgeDude55

Looks stock to me... just has a few kisses on it from the valves now

I think he means to 'aftermarket' break in the middle

zstroken · 03-23-2017, 01:37 PM

No I believe the bowls arent from a 2006.

Ghostman · 03-23-2017, 01:52 PM

Yeah I concur it does not look like a stock 2006 piston.

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biggy238 · 03-23-2017, 02:12 PM

Curious if the truck did anything stressful in the 50 hours of operation prior to failure

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Cflanery88 · 03-23-2017, 03:13 PM

Quote:

Originally Posted by Blueboy

Are you building new motor, or having it built ?

I will be assembling it myself, and installing it back in the truck.

Cflanery88 · 03-23-2017, 03:31 PM

I will go take some more pics of the pistons and verify part numbers but as far as I know it's a stock 06 late spray pattern bowl motor that's never been tore apart besides the headgasket prior to me purchasing it. The crank and pistons have the same logos cast on them but the crank is a Brazil and pistons were made in USA.

DDually · 03-23-2017, 03:42 PM

Quote:

Originally Posted by Cflanery88

I will go take some more pics of the pistons and verify part numbers but as far as I know it's a stock 06 late spray pattern bowl motor that's never been tore apart besides the headgasket prior to me purchasing it. The crank and pistons have the same logos cast on them but the crank is a Brazil and pistons were made in USA.

Everything that happened to your engine is like a mirror image to one I have in my shop right now. It was closer to 900 but with old tuning technology. Cylinder 5, holes on either side, valve prints, cracked piston. It actually took a chunk out of the starter and bent the mount for the trans cooler as well.

spooled05 · 03-23-2017, 03:53 PM

Here's what your piston should look like

[/URL]

03-23-2017, 03:20 AM	#1
Cflanery88 Name: Cflanery88 Title: Too Much Time Status: Not Here Join Date: Feb 2016 Location: Shelby, MI 49455 Member`s Gallery Posts: 536	800hp 2006 5.9 Broken Rod Carnage Figured I'd post the results of a failed cyl#5 factory rod in my 2006. This occurred last June driving down the freeway cruise set at 70mph. Just now had the chance to pull the motor out and tear into it. Rod put nice sized inspection windows on both sides of the block, cracked the piston in half which also had a make out session with the valves, snapped the cam into four pieces, bent intake and exhaust extreme duty pushrods on cyl#5, created a two piece block stiffener, and cracks up both sides of the block about 2" from the deck surface which left the oil pan and remaining 2" of casting holding the back 2 cylinders on the block. Truck ran surprisingly until pulled to the side of the road and turned off with the key. Truck was very well taken care of, serviced every 2-3k miles with rotella T6 and zinc additive, daily driven and was pretty much stock except for the 2100 miles it was driven prior to the Rod letting go. One can speculate on what the cause was but I know for a fact it could have been prevented if I'd of invested in re-building the engine first, and building the bottom end to hold my power goals instead of on more air and fuel with aggressive tuning. I know, and have seen these live at a 1000hp with a stock bottom end but every block, service history, setup, and situation is different. Take my hard learned lesson and build the trans and motor first before dumping your money into a 800-1200hp ticking time bomb. Signature shows hp/Tq and some of the mods at time of failure. I was running a ED billet 63mm over HT60 compounds. I Hope to have my new motor done within the next month or so with a better setup, and built bottom end to eliminate this issue going forward. Thanks. Pics to follow __________________ 06 Dodge Ram 2500 6.4L, Wagler +.080 rods, Hobbit tuned, Exergy150% injectors,Polished s475/87 1:0 A/R Engineered Turbo Billet Wheel,arp625s,14mm main studs,PPE dual fuelers,Hamilton 188/220,extreme pushrods,Fleece bypass/drains/distribution block,110#springs.

03-23-2017, 03:22 AM	#2
Cflanery88 Name: Cflanery88 Title: Too Much Time Status: Not Here Join Date: Feb 2016 Location: Shelby, MI 49455 Member`s Gallery Posts: 536	__________________ 06 Dodge Ram 2500 6.4L, Wagler +.080 rods, Hobbit tuned, Exergy150% injectors,Polished s475/87 1:0 A/R Engineered Turbo Billet Wheel,arp625s,14mm main studs,PPE dual fuelers,Hamilton 188/220,extreme pushrods,Fleece bypass/drains/distribution block,110#springs.

03-23-2017, 03:25 AM	#3
Cflanery88 Name: Cflanery88 Title: Too Much Time Status: Not Here Join Date: Feb 2016 Location: Shelby, MI 49455 Member`s Gallery Posts: 536	__________________ 06 Dodge Ram 2500 6.4L, Wagler +.080 rods, Hobbit tuned, Exergy150% injectors,Polished s475/87 1:0 A/R Engineered Turbo Billet Wheel,arp625s,14mm main studs,PPE dual fuelers,Hamilton 188/220,extreme pushrods,Fleece bypass/drains/distribution block,110#springs.

03-23-2017, 03:26 AM	#4
Cflanery88 Name: Cflanery88 Title: Too Much Time Status: Not Here Join Date: Feb 2016 Location: Shelby, MI 49455 Member`s Gallery Posts: 536	__________________ 06 Dodge Ram 2500 6.4L, Wagler +.080 rods, Hobbit tuned, Exergy150% injectors,Polished s475/87 1:0 A/R Engineered Turbo Billet Wheel,arp625s,14mm main studs,PPE dual fuelers,Hamilton 188/220,extreme pushrods,Fleece bypass/drains/distribution block,110#springs.

03-23-2017, 03:50 AM	#6
Cflanery88 Name: Cflanery88 Title: Too Much Time Status: Not Here Join Date: Feb 2016 Location: Shelby, MI 49455 Member`s Gallery Posts: 536	__________________ 06 Dodge Ram 2500 6.4L, Wagler +.080 rods, Hobbit tuned, Exergy150% injectors,Polished s475/87 1:0 A/R Engineered Turbo Billet Wheel,arp625s,14mm main studs,PPE dual fuelers,Hamilton 188/220,extreme pushrods,Fleece bypass/drains/distribution block,110#springs.

03-23-2017, 03:43 AM	#5
Cflanery88 Name: Cflanery88 Title: Too Much Time Status: Not Here Join Date: Feb 2016 Location: Shelby, MI 49455 Member`s Gallery Posts: 536	__________________ 06 Dodge Ram 2500 6.4L, Wagler +.080 rods, Hobbit tuned, Exergy150% injectors,Polished s475/87 1:0 A/R Engineered Turbo Billet Wheel,arp625s,14mm main studs,PPE dual fuelers,Hamilton 188/220,extreme pushrods,Fleece bypass/drains/distribution block,110#springs.

03-23-2017, 03:52 AM	#7
Cflanery88 Name: Cflanery88 Title: Too Much Time Status: Not Here Join Date: Feb 2016 Location: Shelby, MI 49455 Member`s Gallery Posts: 536	__________________ 06 Dodge Ram 2500 6.4L, Wagler +.080 rods, Hobbit tuned, Exergy150% injectors,Polished s475/87 1:0 A/R Engineered Turbo Billet Wheel,arp625s,14mm main studs,PPE dual fuelers,Hamilton 188/220,extreme pushrods,Fleece bypass/drains/distribution block,110#springs.

03-23-2017, 06:57 AM	#8
Mooner1 Name: Mooner1 Title: Too Much Time Status: Not Here Join Date: May 2009 Location: Kansas Member`s Gallery Posts: 395	Man that sucks! Impressive carnage to say the least, crazy it was still running till you shut the key off. Glad to hear that you are on your way to getting re-powered with a 6.4 build though. __________________ '79 Power Wagon, '83 D-350 crew, '89 Ram Charger, '99 2500 ECLB 5spd, '15 Golf SportWagen TDI

03-23-2017, 07:11 AM	#9
Cflanery88 Name: Cflanery88 Title: Too Much Time Status: Not Here Join Date: Feb 2016 Location: Shelby, MI 49455 Member`s Gallery Posts: 536	Thanks, yeah I was surprised too after looking at everything. Cylinder 5 bore didn't have any damage, all the crank journals were good, and the main/Rod bearings didn't show any abnormal wear. Hopefully the 6.4 build goes as planned and I don't run into to many issues along the way. Everything goes to the machine shop in a couple weeks hopefully. __________________ 06 Dodge Ram 2500 6.4L, Wagler +.080 rods, Hobbit tuned, Exergy150% injectors,Polished s475/87 1:0 A/R Engineered Turbo Billet Wheel,arp625s,14mm main studs,PPE dual fuelers,Hamilton 188/220,extreme pushrods,Fleece bypass/drains/distribution block,110#springs.

03-23-2017, 11:10 AM	#10
Blueboy Name: Blueboy Title: Too Much Time Status: Not Here Join Date: Aug 2006 Member`s Gallery Posts: 993	Are you building new motor, or having it built ?

03-23-2017, 12:22 PM	#11
spooled05 Name: spooled05 Title: Too Much Time Status: Not Here Join Date: Jul 2008 Location: Weatherford ,Tx Member`s Gallery Posts: 832	What was done to that engine in the past , that's not a stock 06 piston . __________________ 05 q/c 4x4 dually,twins,dual fuelers HP tuners,Flux inj., Mitusa gusher,full billet DTT!

03-23-2017, 12:29 PM	#12
DodgeDude55 Name: DodgeDude55 Title: Too Much Time Status: Not Here Join Date: Mar 2013 Location: Waterford,WI Member`s Gallery Posts: 395	Looks stock to me... just has a few kisses on it from the valves now __________________ 2005 Dodge Ram 2500- 3.0 smooth bore puller 2011 Ram 2500- tow rig/ daily driver

03-23-2017, 01:37 PM	#14
zstroken Name: zstroken Title: For $$$ your name here Status: Not Here Join Date: Sep 2006 Location: Western Michigan(by the lake) Member`s Gallery Posts: 23,151	No I believe the bowls arent from a 2006. __________________ 2008 4x4 Megacab, 68RFE 97 Dodge gone.... 24V P-Pump Mafia member #1(retired) Thanks to Mumau Diesel, Goerend Transmission, Northeast Diesel Service!

03-23-2017, 02:12 PM	#16
biggy238 Name: biggy238 Title: Too Much Time Status: Not Here Join Date: Aug 2008 Location: Just North of Wrong Member`s Gallery Posts: 10,862	Curious if the truck did anything stressful in the 50 hours of operation prior to failure Sent from my XT1575 using Tapatalk __________________ Check out @bdmaximusworx 05.5 Campanella White TDi Jetta 5spd 45.5MPG -Little Sexy '10 Silver F250 CCLB 4X4 6.4L cummins Swapped Insta @trash.panda250

03-23-2017, 03:31 PM	#18
Cflanery88 Name: Cflanery88 Title: Too Much Time Status: Not Here Join Date: Feb 2016 Location: Shelby, MI 49455 Member`s Gallery Posts: 536	I will go take some more pics of the pistons and verify part numbers but as far as I know it's a stock 06 late spray pattern bowl motor that's never been tore apart besides the headgasket prior to me purchasing it. The crank and pistons have the same logos cast on them but the crank is a Brazil and pistons were made in USA. __________________ 06 Dodge Ram 2500 6.4L, Wagler +.080 rods, Hobbit tuned, Exergy150% injectors,Polished s475/87 1:0 A/R Engineered Turbo Billet Wheel,arp625s,14mm main studs,PPE dual fuelers,Hamilton 188/220,extreme pushrods,Fleece bypass/drains/distribution block,110#springs.

03-23-2017, 03:53 PM	#20
spooled05 Name: spooled05 Title: Too Much Time Status: Not Here Join Date: Jul 2008 Location: Weatherford ,Tx Member`s Gallery Posts: 832	Here's what your piston should look like [/URL] __________________ 05 q/c 4x4 dually,twins,dual fuelers HP tuners,Flux inj., Mitusa gusher,full billet DTT! Last edited by spooled05; 03-23-2017 at 03:55 PM.