Cummins ISL 400 Engine Failure

[FandM9973]

Not to bring up an old problem with Cummins ISL 400 engines, but I didn't know it was an old problem until we recently (June 2017) experienced catastrophic engine failure and started searching the Internet for answers. I thought my experience might help someone else avoid trouble and "bank- breaking" expenses.

I'm referring to the Cummins ISL 400 (CM850) wrist pin bearing failure recall of 2007. The label in our 2006 Holiday Rambler Endeavor PDQ indicated the vehicle was completed in approximately July of 2005. We purchased it new in February 2007. Apparently, based on a 2007 Cummins recall (well over 2000 engines, 07E-033), Cummins identified a defect in their ISL 400 engines placed in service around October 2005. The recall, issued in May 2007 and amended in September 2007, identified the problem as, "The connecting rod contains a machining defect in the wrist pin bushing of the rod that could cause a seizure of the piston pin, which if allowed to progress, can lead to engine failure with the possibility of the rod rupturing the block cavity, oil and debris on the roadway and vehicle crash."

While heading east on Hwy 20 out of Bend, Oregon, the #6 cylinder wrist pin bearing failed and allowed the piston to puncture the side of the engine case creating a hole approximately 3" in diameter. Our first indication of a problem that day was the sudden jerking of the vehicle, immediate loss of power, the activation of the dash "check engine" light, smoke billowing from behind the coach and a trail of dark liquid dumping of the highway. With no shoulder or pullout available to move to, our vehicle came to rest blocking the only eastbound lane.

Consolidated Tow hauled us to Freightliner Northwest in Redmond, Oregon, where the damage was identified. From a Cummins shop in Oregon I received a $37k estimate to replace the engine with a re-manufactured one which would come with a two year warranty. The long-block option would cost less for the parts but labor would go up because of the parts swap between engines, and no warranty on the long-block. I priced out a used engine for about $11,500 with no warranty; I didn't ask for a quote on the cost of shipping or seek a quote for installation by Freightliner.

In retrospect, from day one of owning the MH my wife and I heard the engine made an unusual rattle sound upon initial start up for the day. After about 30 seconds the unusual rattle would stop. My guess was the sound was just part of the normal, noisy diesel sounds we all experience with vehicles of this type (pulleys, compressors, fans, injectors). I'd asked one of the mechanics who serviced our vehicle about the sound but he wasn't able to hear it or recreate it. I just let it go as normal for that engine. I now wish I'd pursued it and absolutely encourage others to do so if they question any unusual engine noise.

I believe if I'd had a qualified mechanic drop the oil pan and inspect the connecting rods they would have seen the heat discoloration at the wrist pin area of the #6 cylinder where the bearing was failing and maybe even seen the bearing creeping out of its seat in the piston. Again, I would suggest this be done if one owns a similar age Cummins ISL 400. Even the cost of replacing all the piston components would be tens of thousands less than replacing an entire engine.

Anyways, I searched the Internet for information after the Cummins engine failed and found an amazing amount of information about the engine defect we experienced. Much of the information I learned came from iRV2 posts and I appreciated being able to read the reports and experiences of others. I just wanted to share our experience in case it might help others.

It appears our connecting rod contained a machining defect in the wrist pin bushing of the rod which progressed and led to engine failure with the rod rupturing the block cavity and resulted in oil and debris spewing on the roadway. Thank goodness we did not crash or have someone crash into us while we were dead in the road.

We'd only used 22k miles of the original 100k (yes I know, expired) warranty miles for this engine when this problem became painfully obvious; however, I believe symptoms of a problem were apparent from the beginning, and if I'd been more diligent in my questioning something which did not seem normal I feel we could have caught the problem and avoided the life changing costs associated with the engine failure.

I know there are many of these engines with less, similar and more miles on them which have not yet failed. If I had known about this issue with this particular engine manufactured during this time period I would have had an inspection performed. My hope is our experience prevents others from a similar one.

Happy and safe RVing.

[falconman]

It's not really clear to me, yours was within the serial number range? If so, was the recall ever done where they replaced the valve cover and installed a dash light?

[Dutch Star Don]

Yes....do you have an engine with the serial number that Cummins says is part of the recall? If so, did you call Cummins for assistance? I see this is your first post and on many occasions, posts like this are the last. I'll be anxious to see if you respond and what follow up you did with Cummins.

[Mr_D]

Some time ago I found a letter published on the Internet from Cummins lawyers saying that the affected ISL engines carried a lifetime warranty for the wrist pin problem. It's been several years since I say it so I have no way of finding it other than doing a search. I didn't have and ISL at the time so I wasn't too interested in saving a copy either.

BTY: from WA State!

[Fiesta48]

I was concerned about what seemed to me, excessive noise at start up on my 14 ISL9. Never had a diesel before. After about a minute it went away. Then returned later.
Hah the air compressor! Large whooshing noise, bleed off, then it shuts off.
Glad all the noise is in the rear. Sorry about that neighbors.

[DGBPokes]

Sorry for your disaster.....I'm following this thread regarding if your serial number was within the recall group or not. Mine is about 1,000 units
past the recall group.

[vsheetz]

Sorry to hear of your engine failure. I would contact Cummins are press for some assistance with the cost to repair.

The recall related to this issue was not a fix, rather installed a light that supposedly would warn of impending failure and hopefully reduce the damage and cost. Was this recall and light installed to your coach and was there any warning?

When I was looking for a coach, those having engine within the impacted serial number range were automatically out of consideration. While only a small percentage of engines actually failed, I did not want the issue nagging in the back of my mind.

Again, so sorry you have been impacted by this issue. Even at this age, I think Cummins should step up in a meaningful way.

[FandM9973]

Our engine was manufactured a couple months prior to the October 2005 "patient zero" one which was identified in the recall and is not included in the recall group. Seemed to have failed in the same manner as those identified in the recall group. Probably a coincidence.

[FandM9973]

Originally Posted by Mr_D

Some time ago I found a letter published on the Internet from Cummins lawyers saying that the affected ISL engines carried a lifetime warranty for the wrist pin problem. It's been several years since I say it so I have no way of finding it other than doing a search. I didn't have and ISL at the time so I wasn't too interested in saving a copy either.

BTY: from WA State!

Our engine was not within the number range included in the recall. It was manufacture a couple months prior to October 2005. In researching things after our Cummins engine failed, I located the letter I believe you are referring to. I kept a copy for my records and can provide a copy and/or the link to the letter. It appeared to me that legal action was taken against Cummins back in 2007 and Cummins was forced to offer an amended resolution to the problem with their defective engines which provided repairs, etc. for affected engines that were out of warranty. They did not expand the recall group at that time; however, those with engines in the group identified as defective appear to be covered even to this day if the failure is determined to be recall related.

If anyone knows this to not be the case I'd be interested in your thoughts and experiences.

[Playtime III]

I have the ISL that is within the range of serial numbers and the original owner took great care of the coach but I don't have any after market light installed. I am also over the mileage for failure.

Can I get a copy of the letter?

[FandM9973]

Originally Posted by vsheetz

Sorry to hear of your engine failure. I would contact Cummins are press for some assistance with the cost to repair.

The recall related to this issue was not a fix, rather installed a light that supposedly would warn of impending failure and hopefully reduce the damage and cost. Was this recall and light installed to your coach and was there any warning?

When I was looking for a coach, those having engine within the impacted serial number range were automatically out of consideration. While only a small percentage of engines actually failed, I did not want the issue nagging in the back of my mind.

Again, so sorry you have been impacted by this issue. Even at this age, I think Cummins should step up in a meaningful way.

vsheetz, thanks for your input. I was not as wise as you back in 2007 when we went shopping for our rig. I didn't do any research about problems with engines or transmissions. Frankly, when the salesman told me the rig had a Cummins engine I didn't feel I needed to dig into problems with the engine. I, like many others, believed the name Cummins was all I needed to hear. "My bad", as those much younger than I like to say. Manufacturers put these engines in MHs that they sold for hundreds of thousands of dollars to folks like ourselves. Many of those folks placed their trust, and life savings, in the Cummins name.

I agree that Cummins should take a look at my specific engine failure and see what I believe I've identified as the probable cause of the failure. Cummins has not been responsive to my attempts to open up a line of communication regarding this problem. I imagine they would prefer this issue just go away. To me the question is, if my engine failed due to the defective manufacturing process that was identified to Cummins by other users of this engine (those broken down on the roadway over the years), why wouldn't they want to help out with this situation. It can't be all about the money. I've believed in doing the right thing for the right reason. I believe Cummins should step up and at least speak with me about this. I guess they don't believe they need to.

Again, I appreciate any in put from others with thoughts or experiences.

[FandM9973]

Originally Posted by Playtime III

I have the ISL that is within the range of serial numbers and the original owner took great care of the coach but I don't have any after market light installed. I am also over the mileage for failure.

Can I get a copy of the letter?

Try this link. It should take you directly to the NHTSA web page for this recall and has the option to view the related documents ("13 Associated Documents") including the letter and Cummins' amended action (September 18, 2007). Let me know if it works to get you to the site.

I'll try to figure out how to attach the pdf of the document to my post.

Another option is to go to the NHTSA web site, www.nhtsa.gov, choose "Recall", in the middle of the next page choose "Equipment", then choose "Go To Equipment", on the next page (drop down menus) enter/select "Cummins" for Brand and select "ISL CM850" for the Part No/Model No. Should take you to the linked page I above.

Please let me know if you have trouble finding it. Definitely information you should know if your engine is in the recall range. Also not bad info for anyone with an engine of about the same age as my broken one.



https://www-odi.nhtsa.dot.gov/owners...6868&submit=Go

[DAJO]

[QUOTE=Playtime III;3693460]I have the ISL that is within the range of serial numbers and the original owner took great care of the coach but I don't have any after market light installed. I am also over the mileage for failure.

I don't believe that there was a light actually installed. I think and may be wrong that they installed a crankcase pressure sensor and programmed the ECU to turn on check engine light with maybe associated fault codes. The later engines (mine does) have a sensor installed and will give a check engine fault, I have seen it give the fault on mine. If some one knows this is not correct please let me know.

[skyprince]

Originally Posted by Dutch Star Don

Yes....do you have an engine with the serial number that Cummins says is part of the recall? If so, did you call Cummins for assistance? I see this is your first post and on many occasions, posts like this are the last. I'll be anxious to see if you respond and what follow up you did with Cummins.

I'm looking at a Tiffin with Cummins ISL450. Anything in particular I should know?