SAR JK r2.8 Cummins conversion

[superbuickguy]

this should surprise no one, I found the problem in some random place.... the article describes the issue and what I'm hearing

What's That Sound? Gear Rollover And How To Reduce The Noise

Gear rollover is a common noise that comes from a manual transmission. We look at what gear rollover is and how to reduce it.

www.dragzine.com

the article fully describes the noise, its cut-off point and what's happening.... I had the JunK up on the lift today - and that got me going on the google rabbit hole. The noise is most pronounced on the left side of the transmission... now I know why. finally.

up soon, digi dash

 

[Dan Grec]

this should surprise no one, I found the problem in some random place.... the article describes the issue and what I'm hearing

What's That Sound? Gear Rollover And How To Reduce The Noise

Gear rollover is a common noise that comes from a manual transmission. We look at what gear rollover is and how to reduce it.

www.dragzine.com

the article fully describes the noise, its cut-off point and what's happening.... I had the JunK up on the lift today - and that got me going on the google rabbit hole. The noise is most pronounced on the left side of the transmission... now I know why. finally.

up soon, digi dash

Great to hear it's not internal engine trouble!

-Dan

 

[superbuickguy]

Update.
It's at Selkirk Offroad/Land Cruiser shop in Pomeray Idaho (right next to where I live in Sandpoint). They politely told me I could not drive it away until they looked at the noise. Were even going to diagnose for free - but I don't do that, I left it with them to pull the trans and reattach the flywheel.
Backish story. When I put the flywheel on the motor, I didn't get a warm fuzzy, but it torqued okay - but my car sense said it wasn't right. So I did the right thing and just left it. Roll forward to the current troubles, I checked the flywheel, fired it up while on my lift and it looked just fine (there's an access hole in the bellhousing to aid in easy looking. I hauled it up from Kennewick to Sandpoint and basically drove it to their shop (I knew of them in my overland travels).

They're pulling the trans, getting me a bit more clearance (which I had intended to do 'later') and figuring out what is wrong - I'm sure they'll find threadlock on the bolts - which, to me said I felt it was 'okayish' the alternative is I didn't and just failed to torque. Either way - fire me - I don't care but I do care they're into helping me and I am giving them a shoutout because their willingness to simply help for free (their words, "oh, you want us to fix it, we figured you'd just pick it up and fix it yourself" - also, they had to figure out a price to fix....)

 

[superbuickguy]

In the trailer - nice of Cummin's Made-in-Usa box being narrow enough to fit through the side door.

engine vibrated, pounded the heck out of the crank end... this is a new one for me.

Off to Cummins tomorrow. Hopefully they stand behind their warranty.

 

[aer21]

Warranty? What was the problem?

 

[superbuickguy]

Warranty? What was the problem?

bent crank. The bit which bolts to the flywheel is .004 out of alignment (spec is between .0005 and .0001) that is .004 across the flange - I have video of it wobbling while running. It popped the bolts out of 1/2 of the bolts in the crank flange. The pictures show the destruction. At this moment, it sounds like they'll replace the motor.... what, of course, they aren't paying for is the 2k to R&R the motor. Asked (but don't know) if they'll replace the flywheel (it has mirrored damaged). What I don't know beside that is how long it's going to take to get another motor. Apparently there are warranty replacements that are everything but the computer and harness.... cost is 10k in case someone is curious

 

[superbuickguy]

Cummins claims they can't 'demonstrate' the problem even though there's video. While I will continue this fight, I'm buying another crank and flywheel to get this vehicle on the road.... if you imagine the words "when will you buy another Cummins?" the answer is when the devil is buying snowsuits. But I will advertise for them - and just like I advertise for Warn when someone suggest that crap product for anything other then a door stop... and coincidently as well as I advertise for Jeep after their incompetent mechanics couldn't hook a fuel hose and almost burned my house down (and let's not even go to airbag issue, the coolant leaks, or the overall chinese level engineering of their products)....

 

[Dan Grec]

Wow, that's crazy. Sorry you're dealing with all this

If they have the engine right now are they not able to measure the crank and see themselves that it's bent?

-Dan

 

[superbuickguy]

Wow, that's crazy. Sorry you're dealing with all this

If they have the engine right now are they not able to measure the crank and see themselves that it's bent?

-Dan

they're saying the flywheel came loose and bent the crank.

 

[ITTOG]

That would be the equivalent of throwing a pebble at a boulder and the boulder splitting in two. Did they even think about how impossible that would be? (rhetorical)

 

[superbuickguy]

That would be the equivalent of throwing a pebble at a boulder and the boulder splitting in two. Did they even think about how impossible that would be? (rhetorical)

No but, even though I'm an attorney who does product defect litigation, the cost to litigate this would be lunacy. A new crank and new flywheel costs less than court filing fees. It doesn't seem to be a common failure, so no big exemplary damages.... But as I mentioned before, the devil will be buying snowsuits before I ever do another (for myself that it is - I actually have a Fummins project for my excavation guy that probably will happen). I should have bit the bullet and put the a 2.8 like is in my Colorado in her Jeep....though I'm threatening to replace the r2.8 with a 6.2 detroit diesel...

 

[SSF556]

No but, even though I'm an attorney who does product defect litigation, the cost to litigate this would be lunacy. A new crank and new flywheel costs less than court filing fees. It doesn't seem to be a common failure, so no big exemplary damages.... But as I mentioned before, the devil will be buying snowsuits before I ever do another (for myself that it is - I actually have a Fummins project for my excavation guy that probably will happen). I should have bit the bullet and put the a 2.8 like is in my Colorado in her Jeep....though I'm threatening to replace the r2.8 with a 6.2 detroit diesel...

why can't companies just do the right thing nowadays....

 

[superbuickguy]

why can't companies just do the right thing nowadays....

at least it wasn't terrible to buy the parts to fix it? I'm still annoyed but I wonder how much this cost Cummins - I had a neighbor relating this story to me, for some reason he didn't realize that I had posted it .... that kind of advertising isn't something anyone wants....
and an appendix to that - so I finally looked at the diagnosis paperwork. It claimed that they had cut the filter to check for shavings. The filter I put on was still on the motor.... and I still haven't heard from Cummins customer service directly....

 

[AggieOE]

at least it wasn't terrible to buy the parts to fix it? I'm still annoyed but I wonder how much this cost Cummins - I had a neighbor relating this story to me, for some reason he didn't realize that I had posted it .... that kind of advertising isn't something anyone wants....
and an appendix to that - so I finally looked at the diagnosis paperwork. It claimed that they had cut the filter to check for shavings. The filter I put on was still on the motor.... and I still haven't heard from Cummins customer service directly....

That's super frustrating. In hindsight, what would you do different?

 

[superbuickguy]

Updating.
The Jeep is back and not done. At this moment, I'm not sure what, exactly, to say about the shop that was 'helping' me... so moving on. The motor/trans/transfer case is still out

In an effort to make lemonade,. I think I'm going to change the one thing I really don't like about its current setup... the TR 4050. It shifts like a truck transmission - not as good as an NV4500 - and it's for my wife. Whose 6 speed manual handled the 3.8's power just fine for 200k miles. She won't pound on it and the TR 4050 really should be behind something 'worthy' so I'm considering an updated AX15. I have an AR5 as spare for my FJ40, but think I'll be better off just going with the AX15. It's biggest 'good' thing is it's a lot smaller then the TR. No need to cut the floor (which I was really considering given the set-back)

Pictures soon...