Question: 2003 2500HD 8.1 Lifter Failure - Diesel Place : Chevrolet and GMC Diesel Truck Forums
 
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Old 01-27-2020, 04:00 AM   #1 (permalink)
LCPullman
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2003 2500HD 8.1 Lifter Failure

2003 2500hd with 80k mostly towing miles on the truck. Totally stock. It's been well taken care of in terms of oil changes, etc. Just went one morning to start it up and it was squealing like a bad accessory bearing and with in a couple minutes of idle turned to a bad knock.



When I started tearing into it, I found a whole bunch of lifter bearings in the bottom of the pan along with the roller pin from the failed lifter.

Based on the indentation on the bottom of the lifter bore, I'd say that the roller pin came out, caught on the block casting when the cam came around and broke out that side of the lifter.

What I don't know is why the pin came out . . . or whether the roller bearings failed because the pin came out, or the other way around. The lifter roller itself is cracked - many of the needle bearings in the pan are crushed and broken as well.

The cam lobe isn't worn down (just scuffed) so it doesn't appear to have been a long running issue.

The inside of lifter bore itself isn't scarred, so it doesn't seem likely the roller pin was backing out slowly either.



Anyway, just wondering if this is some random fluke, or if anyone has seen anything like this before - or has any ideas why?


I've included a picture of the failed lifter with it's pin and roller - a picture of the bottom of the lifter bore - and a picture of the broken lifter when it was still in the engine

Attached Images
File Type: jpg Lifter broken.jpg (49.4 KB, 2 views)
File Type: jpg Lifter installed.jpg (44.2 KB, 2 views)
File Type: jpg Lifter bore.jpg (39.1 KB, 2 views)
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2003 2500HD 8.1L

Last edited by OkDually; 01-27-2020 at 09:53 AM. Reason: prefix/sig
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Old 01-27-2020, 04:54 AM   #2 (permalink)
davester
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It sounds like a random failure to me. I've been on 4 different forums following GM vehicles, primarily GMT800 gassers, and don't recall seeing many lifter failures. The gas engines for the GMT800's seem pretty long lasting.


Wouldn't surprise me if you throw in a new cam & lifterss, and you get another 200k or more out of it.


I'm approaching 200k miles on my truck with a 6.0L lq4, and it's still running hard. Uses maybe a quart between 5k mile oil changes using synthetic 5w30.

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Last edited by davester; 01-27-2020 at 04:55 AM.
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Old 02-02-2020, 01:20 AM   #3 (permalink)
Snorider
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That's just random bad luck. Not an issue with the all the ones I've been around personally. And on my personal 8.1 I've got 215k or so and while I lost the headgasket and a water pump, that the biggest issues I've had. And it is 80% towing miles.

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Old 02-14-2020, 06:44 PM   #4 (permalink)
LCPullman
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Well, I've got it all put back together with a new cam/all new lifters and its running great - hopefully it stays that way.
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Old Yesterday, 03:06 AM   #5 (permalink)
davester
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Good stuff.
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