Common Problems with Diesel Engine Trucks

Turbo Diesel Problems

Diesel engine trucks are infamous for their power and reliability, making them the best choice for transportation and logistics. However, despite their strong reputation, these trucks come with their Common Problems with Diesel Engine Trucks. From fuel system problems to complex emission systems, diesel engine trucks can encounter many issues that affect performance and expenses.

We will analyze some of the most common issues in renowned diesel engine trucks, looking into their causes and potential solutions. Understanding these problems is crucial, whether you’re a fleet manager, a truck owner, or simply interested in diesel technology for maintaining optimal engine performance and ensuring the durability of your vehicle.

EGR VALVES

The EGR valve limits vehicle emissions by transferring some of the exhaust back into the engine. The valve can be damaged or clogged, resulting in a loss in performance and more emissions.

Failed EGR valves will cause poor acceleration and fuel efficiency, rough idle, and a check engine light.

Cleaning the EGR valve can sometimes fix the problem; however, if it is damaged, it will most likely need to be replaced.

EGR COOLER

The EGR cooler uses engine coolant to absorb heat from recirculated exhaust through its coolant passages or lines.

When it fails, it can rupture and leak coolant into the exhaust or intake. It may also create excessive exhaust pressure, leading to a blown head gasket.

Common signs of failure include white exhaust smoke (steam from boiling coolant) and constantly refilling the coolant reservoir without visible leaks.

If left unfixed, a failed EGR cooler can cause engine failure or require removing the entire intake manifold for cleaning.

DIESEL EMISSION FLUID

Diesel Emission Fluid (DEF), a mix of deionized water and urea, reduces harmful nitrogen oxide emissions in diesel engines.

Contaminated DEF or crystallization in cold temperatures can clog injectors and the pump, restricting flow. This may require cleaning or replacing clogged parts.

DIESEL PARTICULATE FILTER

The Diesel Particulate Filter (DPF) traps soot and diesel particles, preventing them from polluting the air. With proper maintenance, it lasts over 100,000 miles.

When soot levels reach 40-45%, the DPF burns it off through active regeneration. Passive regeneration requires driving about 30 miles at 2,000 RPM to raise exhaust temperatures and clear excess soot.

If regeneration fails, the filter clogs and may need professional cleaning or replacement due to a high risk of damage.

SUSPENSION

Trucks are built for heavy loads and rough terrains, but overloading and harsh conditions can wear down the suspension. Signs of a faulty suspension include steering issues, bumpy rides, or one side sitting lower. Ignoring these problems can cause further damage and increase the risk of accidents.

SHOCK ABSORBERS

The shock absorbers on a truck can be worn out or have a leak, causing the drive to be bouncy and unstable. The fluid inside the shock absorbers is responsible for dampening the bounces on the road, so that the ride remains smooth. When the fluid leaks, the shock absorber’s performance is significantly reduced and ultimately fails.

BALL JOINT

Ball joints, like a hip joint, allow pivoting between the steering knuckles and control arms for smooth suspension movement. They let the suspension move up and down while enabling the wheels to turn.

Faulty ball joints cause vibration, squeaking, and steering instability, which can damage other suspension parts. Regular visual inspections and prompt repairs are essential, as a faulty suspension increases accident risk.

Beyond common issues, some trucks have recurring brand-specific problems that owners should be aware of for better maintenance and troubleshooting.

FORD POWERSTROKE

Introduced in 1994, the 7.3L Powerstroke turbo diesel engine took the truck world by storm. Throughout its nine-year production, the 7.3L Powerstroke turbo diesel engine, with its power and durability, became the best option for truckers, cementing its name in the top 10 diesel engines ever produced in Diesel Power Magazine.

The more recent 6.0L Powerstroke or 6.7L Powerstroke diesel engines have also been popular choices for truck owners, and they are used in the top-selling Ford F series. However, like any engine, they come with their own set of problems.

FUEL SYSTEM

Powerstroke diesel engines often suffer high-pressure fuel system failures due to poor maintenance or contaminated fuel.

This system relies on clean fuel, filtered before reaching the engine, to function properly. Any contamination can cause serious damage.

Clogged filters reduce fuel flow, leading to major issues. To prevent this, use high-quality diesel and replace fuel filters every six months or 10,000 miles.

FUEL INJECTOR FAILURE

With time, the fuel injectors on the Powerstroke get clogged and may even break due to the high diesel line pressure, causing poor fuel efficiency and performance.

You will notice an injector failing with rough idle, misfires, decreased fuel efficiency, or a check engine light. Depending on their condition, the injectors can either be cleaned or replaced.

CHEVY DURAMAX

The Duramax engine debuted in the turbo diesel engine category in the early 2000s with its 6.6L turbocharged V8 variant. Since then, Durmax has had many variations and has been an option in pickups, vans, and medium-sized trucks. Loved by enthusiasts and consumers for superior towing capabilities and performance, Duramax still has some renowned issues.

INJECTORS FAILURE

Mostly due to a design flaw, the fuel injectors on the Duramax engine can fail prematurely as they are sensitive to fuel contamination.

It is recommended by the manufacturer to replace the fuel filters every 30,000 miles to avoid this issue. If the problem still persists, then the injectors will need a replacement.

TURBO

Turbo failure is another common problem that can be caused by many reasons. Dirty air filters when not cleaned or replaced often enough can cause damage to the front of the compressor. In some cases, the clamp that holds the mouthpiece on of the VGT Duramax turbo can come loose and cause suction of debris by the turbo which causes turbo failure.

Turbo failure and damage can be prevented by routine maintenance and care; however, if damaged, it may need a replacement or repair.

DODGE/RAM CUMMINS

The Cummins diesel engine is considered the most durable and reliable diesel engine in the truck community. Being a part of Dodge RAM for 35 years, the Cummins Diesel engine has been a loyal companion for navigating rough terrains, hauling heavy loads, and cruising along the highway. Despite the robust and reliable reputation, the Cummins diesel engine has had its share of problems.

Transmission

The Dodge RAM has been notorious when it comes to transmission problems. The RAM 1500 transmissions have been known for giving their owners headaches, and even the latest 2500 or 3500 still have transmission issues. In mid 2023 many RAM 2500s and RAM 3500s were recalled for a manufacturing defect in the transmission.

If you face erratic shifting or hard shifts between gears, then it’s most likely a transmission problem. In some cases, the transmission can start jerking or shaking severely and can even cause the whole vehicle to shake. Tracing the cause of these issues can be challenging, and may range from something as small as low transmission fluids or transmission fluid leakage to a bad transmission sensor and even gear clutch failure.

68rfe

The 68RFE, introduced by Chrysler in 2007, is a heavy-duty transmission used in RAM 2500 and 3500 trucks. It’s built for towing and hauling but can still face issues.

Overheating is the most common problem, often due to improper maintenance or extreme heat. This can lead to slipping gears or total transmission failure.

The 68RFE’s torque converter can also experience shudder, caused by a failing clutch that causes vibrations and may damage other transmission parts.

Routine maintenance, using the correct transmission fluid, and avoiding aggressive driving and overloading are key to preventing issues.

Transmission problems should be addressed immediately. Consult a professional mechanic for diagnosis and repair.

TURBO

The VGT on Cummins engines faces two common issues: the steel ring inside the turbo getting stuck or the actuator failing to communicate with the computer. This affects exhaust brakes, either reducing braking power or keeping it activated during acceleration.

A failed VGT can cause excessive pressure between the turbo and engine, potentially blowing the head gasket.

Non-VGT turbos can also fail. Over time, oil seals wear out, allowing oil to leak into the intake and exhaust, clogging the intercooler and damaging oxygen sensors. These issues may require cleaning, repair, or replacement of the turbo.

ISUZU NPR DIESEL

The Isuzu NPR diesel engine truck has been a pillar of the Isuzu truck market since 1994. Its low cab forward (LCF) design gives great visibility and maneuverability, making it a perfect choice for urban delivery. With massive payload capacity and towing capacity, the Isuzu NPR Diesel has its fair share of known problems.

BRAKES

The Isuzu NPR, like many commercial trucks, can have brake issues, which are a serious safety concern. You will notice the brake pedal being soft or spongy, or reduced braking efficiency. The cause can either be leaking brake lines or a failing master cylinder.

If you notice a puddle of oil under your vehicle or brake fluid leaking from the lines then you will need a repair ASAP as there is no “temporary’ fix for a leaking braking system. However, if there are no leaks then bleeding the brake lines can fix the issue as air can get trapped inside brake lines. If the problem still exists, then it is a failing master cylinder that has trouble generating pressure for the brakes to work and would need a replacement by a mechanic.

HEAD GASKET

The head gasket on the Isuzu NPR diesel engine is known to fail, mainly because of

overheating and poor engine maintenance. Extreme temperatures cause the engine block and head to expand, causing the head gasket to fail resulting in leakage of coolant and possible mixing with the engine oil.

Common symptoms include white smoke and overheating and can cause further problems like engine failure if not treated promptly. The head gasket will need a replacement by a professional mechanic by removing the engine head and ensuring a precise assembly to form a proper seal.

CONCLUSION

Most of the Common Problems with Diesel Engine Trucks can be prevented just with proper maintenance and routine checkups with a professional. Facing these problems can be troublesome and a recurring nuisance for the truck owners if not treated properly. Fortunately, at ABCO Diesel repair shop, we provide top-quality automotive repairs and services. Whether it is a routine maintenance or complex repairs, our professional medium-duty truck mechanics provide the best of services ensuring that your problems are fixed right the first time. Contact us for an appointment or visit our Orange diesel service shop today.

We also help fleet owners stay compliant with emissions standards — learn more about the Clean Truck Check and how it affects your diesel vehicle. Contact us for an appointment or visit our Orange diesel service shop today.