I think its just bad pistons from Ford. Just my opinion though.

 

I was hoping that wasnt the answer lol are you running aftermarket units?

 

I don't have aftermarket units as they weren't available when I did my build.
I wish i did though, or at least had time to get them coated.

 

This is my #1 concern also about building a Ford. I dont want to dump $10-12k into my truck to improve performance and make it bullet proof, then melt a piston. At that point, it was not a very wise investment. Anyone know the $$$ to upgrade pistons while u have cab off for EGR delete, BOV, upgrading drive train? Should we do injectors at same time?

 

There are lots of factors that can cause cracked pistons. I'm going with the poor casting thing myself. Maybe wetstacking can cause it to happen (to much idling causes low temps in the combustion chamber leaving a tar like mix of unburnt fuel ,moisture and soot may cause a valve to hang open) Who knows just cheap parts.

 

I had one and am saying faulty piston but good to hear you mention the idle thing. My truck idled at Keystone by Revy which is a really high altitude for 5 hours about 2 minutes before it cracked. The Ford mechanic that warrantied it said that he has never seen an engine look so clean. (probably from EGR not opening) and he also said the spray pattern on the piston was perfect. He said there was no way he could deny warranty. The truck went into the dealer stock.

Remember Mahle moved there plant to singapore!

 

I think most piston failures are actually injectors, but some actually are bad pistons too, and naturally the bowl in the piston has a sharp edge around the top, which is a stress riser, so when the heat is really intense there at the top it can start a crack in the bowl and work its way to the edge, but it does say something about the casting when some pistons crack in a straigh line all the way across right in the middle...

 

I guess I need to start looking for a spare motor if I am going to gamble and void the warranty. The 6.4 seems to very reliable 600HP+/- daily driver outside of this issue once u resolve the pressure and tranny issue.

 

Is back pressure palying a role in cracking pistons as well?

 

Back pressure = heat so yes...

 

Im sure it doesnt help. But stock trucks are cracking them to so im not to worried about the extra aftermarket stuff..crossing my fingers though

 

My local tech says its normally #8 cylinder. I think it has something to do with the regen. My truck was running in the 1500's egt under sitting regen. For say 15-20 mins straight. I almost had a heart attack the first time I set up a monitor... There has been a 6.4 at my local dealer with a cracked #8 piston the last 4 out of 5 times I stopped by.

 

I think its hit and miss. I also wonder if the oil cooler jet gets plugged by something.

 

So what is everyone doing to prevent it?? Should we consider replacing injectors as a means of preventive maintenance? Are there aftermarket pistons available for our motors yet or a coating to harden them?

I would rather spend money upfront than have to spend $6-7k for a rebuilt short block. That would be an expensive trip to the shop and it wouldn't even make it faster.:badidea:

 

We've had pretty good success with cryo treated 7.3L and 5.9L Cummins pistons. Haven't done any 6.4L pistons yet. Might be something for you guys building performance motors to look into... give us a call.

 

Any rough idea what the additional cost (labor and coating) would be of doing this while the cab is up for EGR Delete, drivetrain upgrade, tranny, etc???

 

I'm no expert, but I have an hypothesis why they crack. First off pistons that are cast have alot of variences in the porosity of the aluminum, some are physically stronger than others. Second I think the bowl shape plays a big part since its shaped that way for emissions not performance. I think the weak spot is at the top of the bowl where the aluminum is thinnest. I think the cryogenic process would be invaluable and also if a guy were to either use a cnc machine or a router from his garage(*******) and round over the top of the bowl, slightly lowering the compression and reducing the instant combustion pressure and increasing longevity...IMO

 

I think the cryogenic process would be invaluable and also

Agreed, cryogenics does wonders with cast and forged pieces.

 

So exactly how many trucks are experiencing this issue?

 

Doesnt seem that often. Maybe as these motors start to get older we will see more.

 

From what I have seen it seems to be a few different things that lead up to them. The two big ones that I can see are high back pressure and high egts causing the piston to thermal grow and cool more then they are suppose to.

In other words when people buy these big 300+ tunes and run the EGT up north of 1600 degrees the pistons get small cracks in them from the thermal growth. Over many many times of doing this the piston will crack.

If you have supporting mods like EGR delete and extrernal wastegat I truley belive ass long as your not hold high EGT for long period of time the pistons should last longer then most things on the truck.

Of course when a injector sticks and that piston is getting unmetered fuel that going to do some damage also.


Just my 2 cents.

 

From what I have seen it seems to be a few different things that lead up to them. The two big ones that I can see are high back pressure and high egts causing the piston to thermal grow and cool more then they are suppose to.

In other words when people buy these big 300+ tunes and run the EGT up north of 1600 degrees the pistons get small cracks in them from the thermal growth. Over many many times of doing this the piston will crack.

If you have supporting mods like EGR delete and extrernal wastegat I truley belive ass long as your not hold high EGT for long period of time the pistons should last longer then most things on the truck.

Of course when a injector sticks and that piston is getting unmetered fuel that going to do some damage also. QUOTE)

I dissagree. Every cracked piston I have seen was not related to abuse or high EGT's unless it caused a stress crack which did not let go until 20,000 Miles after the abuse, The back pressure is not a concern either on a non spray truck the EP is regulated by the VGT turbo and does not get high at all

 

my melted piston was from a stuck injector

 

Can you pull the pistons with the motor in the truck or do you have to pull the engine? The ? being can you pull the oil pan engine in??

 

I think you can pull the pistons out from the bottom but I imagine removing the bed plate is a huge PITA.. you also have to pull the head(s) to diagnose which piston is cracked so its a big job for sure.:doh:

 

Mine is getting tore down starting Tuesday. I hope I can just change the pistons and be done. I think my number #7 is down. A factory short block is about 4900.00.

 

Keep us posted. I thought the short block was more than that, but I didnt put a lot of research into it.

I would prefer to replace my pistons or have them hardened as Strokin JW mentioned while I had cab off and engine tore apart for drivetrain, EGR delete and tranny to make motor more bullet proof. For me it's piece of mind and like an insurance policy.

 

ouch, what a kick in the teeth!

what did they quote you for?

 

Just 1200 for the tear down. It would cost me 2000 to get my truck and trailer home to do the work myself. Plus time off. I kind of want to replace all the injectors with ede60 and the fass 165 plus a pump mod of coarse. Are the ceramic pistons any better?

 

Anybody thaught about the advanced timing creating high cylinder pressures. And all that advanced timing/late injection is from the dpf cycling system and tuners

 

how does that work for those that dont have DPF's?

 

Ok here's my questions, if a guy is doing a rebuild and performance upgrades, even if a new set of pistons are cryo treated and ceramic coated tops....do you think a bad injector still wreck that piston????

 

I would say its still possible, but a lot let probable.

Edit: For the 2650.00 Empire Diesel pistons should never fail.

 

Maybe I will just take my truck to Elite or Rudy's and get the WORKS I dont want to be pulling my 5th wheel and have any issues.

Maybe the new reflash will help and we should also consider replacing injectors as part of our build for preventative maintenance purposes. i think new injectors are less likely to hang than our injectors with current miles and time on them.

 

A stuck open injector would ruin any piston..one of the reasons i put an airdog on my truck for the extra protection.

 

Good call. I toy'd with that idea too. Decided to go a different way thou, Elite takes all my money haha.