A picture is the only way to describe this...

http://i39.photobucket.com/albums/e156/bondjames85/DSCN1300.jpg

I was pulling a load (about 5,000 lbs) up a pretty good incline at about 55mph when it sounded like I had driven into an ambush and was taking machine gun fire...

had a little flashback moment (good thing my gun was not in reach)

regained composure and pulled to the side of the road.

It was not a knock, like a rod knock, but the same timing of the sound... *bang, bang bang* Popped the hood and found instantly where it was from. Pretty easy considering it was like someone was firing a gun under the hood.

The glow plug on the #2 piston had shot its heating element out, it was still hanging by the wire and the housing was still in the block. There was a small hole in the center of the plug (as seen in pic) and was obvious why it sounded like a gun. Over a liter of air was shooting out this glow plug every time the piston fired...

Possible Causes I suspect:

My pump is out of time, been driving like that all weekend. Got it dialed in to where the truck runs,drive, starts good but the computer isn't quite satisfied yet. Still need to get a hold of a programer, but its a holliday weekend and I've got a new IP coming on tues... Could have been over advanced under load pulling that hill and caused the damage to the plug... Strange that I didn't loose the headgaskets first though...

An injector stuck. The truck does need new injectors. they have at least 70k miles, could be 170k for all I know. I've also got a new set of those on the way as well. Still, could have lost a gasket, why the plug??


I still had the old glow plugs with me (had just replaced those plugs not 200 miles before, Delphi units) and I screwd the broken one out, put a new one in, fired the truck up, and have gone 200 miles since then.

Has anyone else ever had this happen?

Any Ideas on the cause?

I've seen a similar picture but it was on a mechanical pump 6.5 that over revved and overtemped.

If you have a laptop get carcode. $125 IIRC someone at another site has a writeup on howto time IP with it.

I've seen a similar picture but it was on a mechanical pump 6.5 that over revved and overtemped.

Engine RPM was about 2,500
Temp was 190

If you have a laptop get carcode. $125 IIRC someone at another site has a writeup on howto time IP with it.

Hmm... laptop, $800-$1500, my pickup... $500 (+ $700 in parts)

Wish I could afford the laptop! :) any other tips on a good code reader? Would like to do my 96 with it to...

Doesn't take much of a laptop find an old one someone is getting rid of. I got one for free.

With the same cheap laptop you can get software from Engh motors to do obd1

A picture is the only way to describe this...

http://i39.photobucket.com/albums/e156/bondjames85/DSCN1300.jpg

I was pulling a load (about 5,000 lbs) up a pretty good incline at about 55mph when it sounded like I had driven into an ambush and was taking machine gun fire...

had a little flashback moment (good thing my gun was not in reach)

regained composure and pulled to the side of the road.

It was not a knock, like a rod knock, but the same timing of the sound... *bang, bang bang* Popped the hood and found instantly where it was from. Pretty easy considering it was like someone was firing a gun under the hood.

The glow plug on the #2 piston had shot its heating element out, it was still hanging by the wire and the housing was still in the block. There was a small hole in the center of the plug (as seen in pic) and was obvious why it sounded like a gun. Over a liter of air was shooting out this glow plug every time the piston fired...

Possible Causes I suspect:

My pump is out of time, been driving like that all weekend. Got it dialed in to where the truck runs,drive, starts good but the computer isn't quite satisfied yet. Still need to get a hold of a programer, but its a holliday weekend and I've got a new IP coming on tues... Could have been over advanced under load pulling that hill and caused the damage to the plug... Strange that I didn't loose the headgaskets first though...

An injector stuck. The truck does need new injectors. they have at least 70k miles, could be 170k for all I know. I've also got a new set of those on the way as well. Still, could have lost a gasket, why the plug??


I still had the old glow plugs with me (had just replaced those plugs not 200 miles before, Delphi units) and I screwd the broken one out, put a new one in, fired the truck up, and have gone 200 miles since then.

Has anyone else ever had this happen?

Any Ideas on the cause?just a bad plug i would say.The core is pressed in the body with the lead insulated.What goes in ,might come out again.

Shit happens,i would not get paranoid about it,altough i can appriciate the :wtf1:moment,and:confuzeld right after.

Had the same thing happen about 3 yrs back. I hadn't changed the GP's in two + years, was going down the hwy bout 65 mph. Bought new plugs and installed. S--t happens, not to worry!

Had the same thing happen about 3 yrs back. I hadn't changed the GP's in two + years, was going down the hwy bout 65 mph. Bought new plugs and installed. S--t happens, not to worry!

just a bad plug i would say.The core is pressed in the body with the lead insulated.What goes in ,might come out again.

Shit happens,i would not get paranoid about it,altough i can appriciate the :wtf1:moment,and:confuzeld right after.


Now that I've driven a few miles since then I'm not as concerned about it. I just wanted to make sure...

A faulty glow plug did cross my mind, like I said, if something was REALLY wrong I think I would have lost the headgaskets. Luckily I was able to replace the plug there along side of the highway and just keep going.

On another note, a while back I posted some pictures of the work I was doing on this truck. Did a little bit on the glow plugs and made a smart A$$ comment about the guys who say they can change the passenger side plugs without removing the inner fender... well, I've found that it CAN be done. (if you have to) Getting past the hot turbo, hot manifold, and having every truck that blows past you slam the hood down on you just adds to the excitement!

I've never had the inner fender out on mine and have replaced the glows 3-4 x. Plus had my turbo off a couple of times to rebuild it.

I've never had the inner fender out on mine and have replaced the glows 3-4 x. Plus had my turbo off a couple of times to rebuild it.

I worked on helicopters in the Marines. They require a spectacular amount of contortions to get to just about anything! Its amazing what a guy can do when he has to! My comment was not that it couldn't be done, but that it would be much easier with the fender out. At the time I was doing a turbo, glow plugs, snorkle removal, and a '98 filter box conversion. The inner fender only took me 5 minutes with an air ratchet and made the rest of that those jobs SO much easier...

I have running boards so it would take longer.

I have running boards so it would take longer.

True... guess I didn't think about having those. I ditched mine about 5 minutes after I started driving this truck. They were both bent up so far that they hit the doors when you opened them. (didn't help that there were no bushings left in the doors and they dropped about 1 1/2 when you opened them)

Glad you survived the attack.
PTSD can raise its ugly head at any time, that's partly why I live away from airstrips and avoid flying. Sucks to make emercency repairs on the roadside, possibly fatal. Saw that 2X.

Are you stockpiling the 6.2s or are they available?

Glad you survived the attack.
PTSD can raise its ugly head at any time, that's partly why I live away from airstrips and avoid flying. Sucks to make emercency repairs on the roadside, possibly fatal. Saw that 2X.

Are you stockpiling the 6.2s or are they available?

Good thing I wasn't "Motor-T" when I was in or that that would have REALLY freaked me out... or like my younger brother who was infantry. Everything freaks him out.

I hate doing anything on the roadside. Luckily I was on HWY 212 going to the ranch in Colony Wyoming. Its Almost perfectly strait for 30 miles and has very low traffic volume. Luckly, when living in Oceanside, CA and driving my $50 5.7 diesel olds, I only broke down on the freeway once and I was able to coast down and off ramp and get into a parking lot. I don't think I would have considered trying to do anything parked there along the "5". I don't know if I'd even change a tire if I could help it!

As far as the 6.2's; I'd like to hang on to one or two of them, but the rest are pretty much up for grabs. Feel free to PM me...

Its been a long time since this post, but I never got around to posting the cause of the failure...

As with many things in life this one can be blamed on "operator error"

I had taken the truck in to get the IP timed, but the shop couldn't get it timed, said it could get close, but the pump was bottoming out (couldn't slide it any farther) My concern was that, when I had repalced the timing chain, perhaps I had installed it wrong. After much deliberation I took the truck apart to see...

I posted the extensive list of things I replaced, but didn't mention that I had pulled out the crank sensor to clean the VERY dirty timing chain cover. It was so covered in oil that it was hard to remove. When I finally got it out the little bracket that holds the sensor in place had separated. The sensor has 4 little cogs and the bracket, 4 little slots. I had never had one out before so I didn't realize that most of them are in one piece, meaning they cannot be installed wrong. Well, I had just put mine back into the bracket they way I THOUGHT it had come out. Turns out I was wrong.

You can install a CPS upside down, making the pump think the motor is about 13.5 degrees farther retarded than it is...

That little oopsie caused the engine to run poorly, and under load, melt the glow plugs. After fixing the problem, The engine is much harder starting now with excessive white smoke and rough idle at start up, even with the new glow plugs. (all of the other plugs were nearly as bad as this one) There is a neat little "chimney" of smoke that comes out of the oil dipstick now and I'm sure the pistons were all but ready to let loose before the plugs went. She still runs and drives, even recently went on a 1800 mile trip to Louisiana with her, but it won't be long until I'm in the market for a new motor...

Not a huge loss, with almost 200k miles I was thinking it would be time to re-ring this motor, just looks like it will be sooner rather than later!!!

Here are a few pics from my IP install, thought ya'll might get a kick out of them...

The mice had decided to make a home under my IP...
http://i39.photobucket.com/albums/e156/bondjames85/0907091407a.jpg
http://i39.photobucket.com/albums/e156/bondjames85/0909091512a.jpg

Rebuilt 96 IP to replace the old 94
http://i39.photobucket.com/albums/e156/bondjames85/0911091430a.jpg