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Noodle1967
New Member
USA
5 Posts |
 Posted - 04/20/2011 : 08:38:38 AM
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| Hi,I am new to the forum.I have read many good tips and ideas on here that have helped me out of a jam.I am a mechanic with 26 years experience at an independent shop which is also a Cummins dealer.If any one needs anything looked up on any Cummins engine let me know.I hope some one can help with my latest problem.I have a 04 maxxforce dt that is black smoking on acceleration.Not every time,but when it does it is very sluggish.So far it has had replaced:primer pump,cam sensor,tps sensor,turbo and actuator.Injectors pulled and checked,all new o-rings on injectors and high press. manifold.Valves adjusted,grounds on eng.,starter,and batteries cleaned.It has had the egr cooler replaced in the last year.Everything I have tried seems to make it smoke more often and run more sluggish when it does smoke, especially after I put the injectors back in.Everything I have changed had one problem or another,cut orings,jerky actuator,turbo vanes damaged(from jerky actuator),wrong spacer behind oil manifold o-rings,leaking primer pump.Btw the fuel is black.I think I covered everything.Thanks in advance.If I have offended anyone by not being a bus tech I am sorry!Thanks again,Ron |
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stovebolt
Active Member
37 Posts |
Posted - 04/20/2011 : 12:21:21 PM
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| Ron, I don't mean to insult your intelligence, but have you checked you fuel filter and your air filter? It sounds like you have your bases covered pretty good |
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Noodle1967
New Member
USA
5 Posts |
Posted - 04/20/2011 : 12:28:47 PM
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| Yes,new filters all around,changed oil (15w40 rotella).Even checked batteries! |
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Fastback
Top Member
1500 Posts |
Posted - 04/20/2011 : 12:54:54 PM
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Not to nitpick but I don't believe a 2004 "maxxforce dt" exists.
A 2004 would simply be a DT466. 
A Maxxforce DT would be 2007 emission standard or newer. |
Why yes, the ORIGinal CHARGER is a Fastback |
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Noodle1967
New Member
USA
5 Posts |
Posted - 04/20/2011 : 1:03:16 PM
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| On my isis dvd the 466 does not have anything about egr setup or the internal oil manifold,but the maxxforce manual does.Not saying that makes it a maxxforce but it is the only manual in isis that covers what is on this engine.I am by no means an expert on IH engines!(or any other ones for that matter!) |
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Noodle1967
New Member
USA
5 Posts |
Posted - 04/20/2011 : 1:49:19 PM
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| Like I said not an expert!I was looking for the manual under the engine category,the 466 w/egr systeme is not there.It is under the truck model (ie 4400)category.That manual says to disassemble the filter can if there was bad fuel or the primer pump was replaced for air leakage.I guess my next step is to try to clean/inspect the filter can and replace the regulator.Thanks for the heads up,now I am at least looking at the correct service manual!I will let you all know how it goes. |
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IBTMech
Top Member
USA
973 Posts |
Posted - 04/21/2011 : 3:09:56 PM
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If your fuel is black and it's a DT466E, you have a leaking injector oil seal.
If it's an '04 you have a DT466E or a very early DT egr version. Your VIN should identify that. You indicated a VGT which suggests an '05 or '06. Black smoke would indicate an excess fuel/lack of air issue. Have you checked your exhaust backpressure?
What are your codes? There must be some. Do you have engine diagnostic equipment? You have replaced a mess of parts with no results. Have you consulted anyone familiar with these engines?
Oh. Maybe that's why you're here......
Concerning the turbo issue, the reason for the jerky actuator is sticking turbo vanes due to corrosion. I have disassembled, cleaned and reassembled many VG turbos (3 hour job) without replacing the actuator and they run fine afterwards ($17 seal kit). The bummer is getting those stainless steel cap screws out of the cast iron housing...... lots of gentle heat and weasel piss required. The Maxxforce turbos don't have this issue so far.
It's a chronic problem with the early VGTs due to lack of use, mostly. |
If it doesn't fit, FORCE it.
If it breaks, well, it needed replacing anyway.
Pullin' wrenches for 45 years. |
Edited by - IBTMech on 04/21/2011 5:45:39 PM |
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Noodle1967
New Member
USA
5 Posts |
Posted - 05/02/2011 : 12:37:06 PM
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| Fuel is staying clear now.Replaced fuel filter housing,had tank cleaned out because of rust.No codes(checking with prolink iq)Everything I do makes it smoke and hesitate more!The injectors were checked by a pump shop.I thought those injectors could only be checked by a select few places in the country.Has any body had this style injector checked with any success?The way it acts is like one or more is sticking and either over fueling or just slobbering in the cylinder.I have called the IH dealer(where we spend $3-$4k every month)all they say is bring it over!Thanks for your time. |
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maxxforce dt black smoke
