5 Signs Your Cummins Engine Needs an Overhaul

With rising maintenance costs due to extended truck lifecycles after COVID-19, hefty dealer overhauls reaching $40,000 can be a major blow. But fear not! Here's the good news: proactive maintenance and timely truck engine overhauls can extend your truck's lifespan to a whopping 750,000 miles or more while potentially saving you thousands. This article, brought to you by Steel Chariots Truck Repair, will equip you with the knowledge to recognize the key signs your engine needs an overhaul so you can keep your rig running smoothly and your business thriving.

The Impact of Extended Truck Life Cycles

The trucking industry has seen a shift in recent years. Due to COVID-19, fleets are keeping their trucks on the road longer, leading to a rise in maintenance costs. Engine overhauls are a major expense, as dealer semi-truck engine overhauls can reach a staggering $40,000. However, there's a way to be strategic. Experts recommend considering basic overhauls, like re-ringing the engine and replacing rods and bearings. This cost-effective approach, bringing expenses down from a complete engine overhaul, not only extends your truck's lifespan but also keeps maintenance costs manageable in the long run. Imagine the savings — that's money you can reinvest in your business and keep your fleet operating efficiently.

Understanding Truck Engine Overhauls

A truck engine overhaul is a major undertaking, but it's an essential procedure to ensure the longevity and performance of your vehicle. During a truck engine overhaul, a qualified mechanic will disassemble the engine, clean and inspect all components, and replace any worn or damaged parts. This can include pistons, rings, bearings, valves, and gaskets. In some cases, the engine block or head may also need to be machined or replaced.

Overhauls tend to be done in one of two ways: “in-frame” or “out-of-frame.” In-frame engine overhauls are faster, cheaper, and easier. It involves only replacing pistons, rings, cylinder liners, bearings, and other accessible components, as the engine isn’t pulled out from the truck. Out-of-frame engine overhauls are more comprehensive and complex — a mechanic will inspect and replace deeper internal components like the crankshaft.

Why Consider a Truck Engine Overhaul?

While a truck engine overhaul is a significant investment, it can be far more cost-effective than replacing the entire engine (or trading the truck!). Furthermore, a well-maintained engine is more fuel-efficient, reliable, and less likely to experience breakdowns on the road. This can save you money on fuel costs and lost productivity.

The Workhorse Engine: Cummins and the Need for TLC

Cummins engines are renowned for their durability and reliability. They are a popular choice for powering semi-trucks due to their ability to handle the demands of long-haul transportation. However, even the most robust engines, from the classic Cummins ISX to the advanced Cummins X15, need attention. By identifying the warning signs that your Cummins engine needs an overhaul, you can avoid costly breakdowns and keep your truck running smoothly for miles to come.

5 Signs It's Time for a Cummins Truck Engine Overhaul

No. 1: High Mileage

Every engine has a lifespan, and Cummins engines are no exception. Generally, exceeding 750,000 miles is a strong indicator that a truck engine overhaul might be necessary. Think of it as a major milestone — a chance to ensure your engine continues to perform at its peak for years to come.

No. 2: Burning Oil Smell

If your truck’s engine is chugging oil, sometimes you’ll get a strong burning oil smell. This is a telltale sign of overheating, which can cause internal engine components to warp or seize, leading to expensive repairs. If you detect this smell, pull over immediately and shut down your engine to prevent further damage. Schedule a prompt inspection to diagnose the cause of the overheating and determine if a truck engine overhaul is necessary.

No. 3: Decreased Oil Viscosity

Healthy engine oil has a specific viscosity, which affects its ability to lubricate moving parts. If your oil feels thin and watery, it's a sign of fuel dilution. This can occur due to worn piston rings or injector issues, and reduced lubrication can lead to increased friction and premature engine wear. Regular oil changes and oil analyses are important preventative measures. If you suspect fuel dilution, it's a good idea to consult with a mechanic to determine the cause and discuss the possibility of a truck engine overhaul.

No. 4: Unusual Knocking Sounds

Knocking sounds coming from your engine are never a good sign. These can indicate worn bearings, loose connecting rods, or other internal problems. Ignoring these sounds can lead to catastrophic engine failure. If you hear any abnormal knocking sounds, pull over immediately and shut down your engine. Have your truck towed to a qualified mechanic for a diagnosis — depending on the severity of the problem, a truck engine overhaul might be necessary.

No. 5: Noticeable Loss of Power

A significant decrease in engine power can be a sign of various issues, including worn piston rings, clogged fuel injectors, or turbocharger problems. While not always a direct indicator of needing a truck engine overhaul, a noticeable loss of power can point to underlying problems that may necessitate an overhaul in the near future. If you experience a power loss, consult with a mechanic to diagnose the cause and determine the best course of action.

Taking Proactive Steps: Preventing the Need for a Truck Engine Overhaul

Thankfully, there are ways to push a Cummins truck engine overhaul down the line. Some proactive steps you can take include:

Follow the recommended maintenance schedule outlined in your truck's owner's manual. This includes regular oil changes, filter replacements, and inspections of critical components.

Use high-quality engine oil and lubricants. These products are formulated to protect your engine from wear and tear.

Warm up your engine before driving, especially in cold weather. This allows the oil to circulate properly and lubricate all moving parts.

Avoid overloading your truck. This puts extra strain on the engine and can lead to premature wear.

Pay attention to warning lights and gauges on your dashboard. These can alert you to potential problems before they become major issues.

Schedule regular inspections by a qualified mechanic. A mechanic can identify potential problems early on and recommend repairs before they become more serious.

Final Words

A truck engine overhaul is a significant undertaking, but it's an investment that can save you money and frustration in the long run. If you suspect your truck’s engine may need an overhaul, don't wait until a minor issue becomes a major breakdown. Steel Chariots Truck Repair has a team of experienced mechanics qualified to handle all your diesel engine overhaul needs, from routine maintenance to complex repairs. Our experts can diagnose the problem, recommend the most cost-effective solution, and get your truck back on the road quickly and efficiently. Contact Steel Chariots Truck Repair today to schedule an inspection and ensure your truck keeps powering your business for years to come.