Road trip blues

[davidkerryedwards]

This roadtrip is turning into a sequence of mechanical problems. After we got
the idler
pulley repaired in MO, we made it to WV when the crossover pipe (a second rate
flexible
pipe) failed. FMCA road service sent out a mechanic who removed the broken end
and re
attached it. We got down the road 40 miles and it failed again,. I reattached
it myself and
we limped into Cumberland MD on Saturday where we waited until this morning(in a
shopping mall parking lot) for an exhaust shop to open. Jim's transmissionn and
exhaust
did an excellent quick job and we were on the road by 11am. A mile down the
road the
engine quit suddenly at 60mph. Pulled over, restarted it and set off again.
this happened
three times in 5 miles. I called FMCA road service again since it was dangerous
to drive
since we lost power steering when the engine quit. Were towed to Keyser WV
($431--buy
road service!) where we are currently in a motel. The current diagnosis is that
when the
crossover pipe failed it sooted up the air cleaner resulting in very high vacuum
in the
intake which sucked down a rubber hose cutting off all air flow to the engine
and shutting
it down. We're waiting for a new air filter to arrive by UPS tomorrow. I had
thought the
turbo was failing and seizing up, so if this diagnosis is correct, it's a much
more simple
fix. The diagnosis makes a fair amount of sense since the shut down problems
occured
after the crossover pipe was properly fixed with a solid pipe which would make
the turbo
operate more efficiently than the loosely attached prior repair.
We hope to make it to DC sometime this summer and then have a less eventful
journey up
to NYC, Montreal, and back to Denver.
If anyone has any better diagnoses, jump in. The air filter is within a couple
of feet of the
ccrossover pipe and it was completely black when removed. Apart from a turbo
failing, I
can't think of any other explanation. It definitely had fuel since the max fuel
light was on
when it happened and it shot out lots of gray smoke upon start up. The only
other thing
that could seem to cause a diesel to stop running is lack of compression, lack
of timing, or
lack of air.

Kerry
82 FC 35
Denver
Singing the blues in WV (or should that be bluegrass?)

[Scott Forman]

OK...dumb question...what/where is a "crossover pipe"?

Scott Forman
82 FC35RB
Memphis

--- In WanderlodgeForum@yahoogroups.com, "davidkerryedwards"
wrote:
>
> This roadtrip is turning into a sequence of mechanical problems.
After we got the idler
> pulley repaired in MO, we made it to WV when the crossover pipe (a
second rate flexible
> pipe) failed. FMCA road service sent out a mechanic who removed
the broken end and re
> attached it. We got down the road 40 miles and it failed again,.
I reattached it myself and
> we limped into Cumberland MD on Saturday where we waited until this
morning(in a
> shopping mall parking lot) for an exhaust shop to open. Jim's
transmissionn and exhaust
> did an excellent quick job and we were on the road by 11am. A mile
down the road the
> engine quit suddenly at 60mph. Pulled over, restarted it and set
off again. this happened
> three times in 5 miles. I called FMCA road service again since it
was dangerous to drive
> since we lost power steering when the engine quit. Were towed to
Keyser WV ($431--buy
> road service!) where we are currently in a motel. The current
diagnosis is that when the
> crossover pipe failed it sooted up the air cleaner resulting in
very high vacuum in the
> intake which sucked down a rubber hose cutting off all air flow to
the engine and shutting
> it down. We're waiting for a new air filter to arrive by UPS
tomorrow. I had thought the
> turbo was failing and seizing up, so if this diagnosis is correct,
it's a much more simple
> fix. The diagnosis makes a fair amount of sense since the shut
down problems occured
> after the crossover pipe was properly fixed with a solid pipe which
would make the turbo
> operate more efficiently than the loosely attached prior repair.
> We hope to make it to DC sometime this summer and then have a less
eventful journey up
> to NYC, Montreal, and back to Denver.
> If anyone has any better diagnoses, jump in. The air filter is
within a couple of feet of the
> ccrossover pipe and it was completely black when removed. Apart
from a turbo failing, I
> can't think of any other explanation. It definitely had fuel since
the max fuel light was on
> when it happened and it shot out lots of gray smoke upon start up.
The only other thing
> that could seem to cause a diesel to stop running is lack of
compression, lack of timing, or
> lack of air.
>
> Kerry
> 82 FC 35
> Denver
> Singing the blues in WV (or should that be bluegrass?)
>

[davidkerryedwards]

Crossover pipe takes the exhaust from one manifold over to join up with the
exhaust from
the other. In my case it takes the right exhaust over to the left side where
both power the
turbo. It broke on the left side right near the intake for the air cleaner
which is in front of
the left wheel. I had to drive it a couple of miles to an exit and it was
spewing huge clouds
of black smoke because the turbo was barely turning since the exhaust from both
sides
was following the path of least resistance which was out of the broken pipe
instead of thru
the turbo. Without the turbo'd air it was way overfueled for the amount of air
it was
getting.
By the way, it is probably worth noting that the crossover pipe had probably
cracked
before it broke resulting in less air and I had noticed the egt's were running
about 150
degrees hotter than normal. They could get over 1200 degrees if I wasn't
careful on a
steep hill. This tells me a richer or overfueled engine could have dangerous
EGT levels
pretty easily.

Kerry

--- In WanderlodgeForum@yahoogroups.com, "Scott Forman" <sforman@...> wrote:
>
> OK...dumb question...what/where is a "crossover pipe"?
>
> Scott Forman
> 82 FC35RB
> Memphis
>
> --- In WanderlodgeForum@yahoogroups.com, "davidkerryedwards"
> wrote:
> >
> > This roadtrip is turning into a sequence of mechanical problems.
> After we got the idler
> > pulley repaired in MO, we made it to WV when the crossover pipe (a
> second rate flexible
> > pipe) failed. FMCA road service sent out a mechanic who removed
> the broken end and re
> > attached it. We got down the road 40 miles and it failed again,.
> I reattached it myself and
> > we limped into Cumberland MD on Saturday where we waited until this
> morning(in a
> > shopping mall parking lot) for an exhaust shop to open. Jim's
> transmissionn and exhaust
> > did an excellent quick job and we were on the road by 11am. A mile
> down the road the
> > engine quit suddenly at 60mph. Pulled over, restarted it and set
> off again. this happened
> > three times in 5 miles. I called FMCA road service again since it
> was dangerous to drive
> > since we lost power steering when the engine quit. Were towed to
> Keyser WV ($431--buy
> > road service!) where we are currently in a motel. The current
> diagnosis is that when the
> > crossover pipe failed it sooted up the air cleaner resulting in
> very high vacuum in the
> > intake which sucked down a rubber hose cutting off all air flow to
> the engine and shutting
> > it down. We're waiting for a new air filter to arrive by UPS
> tomorrow. I had thought the
> > turbo was failing and seizing up, so if this diagnosis is correct,
> it's a much more simple
> > fix. The diagnosis makes a fair amount of sense since the shut
> down problems occured
> > after the crossover pipe was properly fixed with a solid pipe which
> would make the turbo
> > operate more efficiently than the loosely attached prior repair.
> > We hope to make it to DC sometime this summer and then have a less
> eventful journey up
> > to NYC, Montreal, and back to Denver.
> > If anyone has any better diagnoses, jump in. The air filter is
> within a couple of feet of the
> > ccrossover pipe and it was completely black when removed. Apart
> from a turbo failing, I
> > can't think of any other explanation. It definitely had fuel since
> the max fuel light was on
> > when it happened and it shot out lots of gray smoke upon start up.
> The only other thing
> > that could seem to cause a diesel to stop running is lack of
> compression, lack of timing, or
> > lack of air.
> >
> > Kerry
> > 82 FC 35
> > Denver
> > Singing the blues in WV (or should that be bluegrass?)
> >
>

[Chris Reed]

Aside from belts and hoses, what else can I do as far as preventive maintenance
to make sure I dont end up on the side of the road....I can't imagine going
through what Kerry is now....what else should I be checking under this bus?
Chris Reed
83 FC35 SB
Plant City, FL
Waiting for new/rebuild engine cooling fan....

davidkerryedwards wrote:
Crossover pipe takes the exhaust from one manifold over to join up
with the exhaust from
the other. In my case it takes the right exhaust over to the left side where
both power the
turbo. It broke on the left side right near the intake for the air cleaner which
is in front of
the left wheel. I had to drive it a couple of miles to an exit and it was
spewing huge clouds
of black smoke because the turbo was barely turning since the exhaust from both
sides
was following the path of least resistance which was out of the broken pipe
instead of thru
the turbo. Without the turbo'd air it was way overfueled for the amount of air
it was
getting.
By the way, it is probably worth noting that the crossover pipe had probably
cracked
before it broke resulting in less air and I had noticed the egt's were running
about 150
degrees hotter than normal. They could get over 1200 degrees if I wasn't careful
on a
steep hill. This tells me a richer or overfueled engine could have dangerous EGT
levels
pretty easily.

Kerry

--- In WanderlodgeForum@yahoogroups.com, "Scott Forman" <sforman@...> wrote:
>
> OK...dumb question...what/where is a "crossover pipe"?
>
> Scott Forman
> 82 FC35RB
> Memphis
>
> --- In WanderlodgeForum@yahoogroups.com, "davidkerryedwards"
> wrote:
> >
> > This roadtrip is turning into a sequence of mechanical problems.
> After we got the idler
> > pulley repaired in MO, we made it to WV when the crossover pipe (a
> second rate flexible
> > pipe) failed. FMCA road service sent out a mechanic who removed
> the broken end and re
> > attached it. We got down the road 40 miles and it failed again,.
> I reattached it myself and
> > we limped into Cumberland MD on Saturday where we waited until this
> morning(in a
> > shopping mall parking lot) for an exhaust shop to open. Jim's
> transmissionn and exhaust
> > did an excellent quick job and we were on the road by 11am. A mile
> down the road the
> > engine quit suddenly at 60mph. Pulled over, restarted it and set
> off again. this happened
> > three times in 5 miles. I called FMCA road service again since it
> was dangerous to drive
> > since we lost power steering when the engine quit. Were towed to
> Keyser WV ($431--buy
> > road service!) where we are currently in a motel. The current
> diagnosis is that when the
> > crossover pipe failed it sooted up the air cleaner resulting in
> very high vacuum in the
> > intake which sucked down a rubber hose cutting off all air flow to
> the engine and shutting
> > it down. We're waiting for a new air filter to arrive by UPS
> tomorrow. I had thought the
> > turbo was failing and seizing up, so if this diagnosis is correct,
> it's a much more simple
> > fix. The diagnosis makes a fair amount of sense since the shut
> down problems occured
> > after the crossover pipe was properly fixed with a solid pipe which
> would make the turbo
> > operate more efficiently than the loosely attached prior repair.
> > We hope to make it to DC sometime this summer and then have a less
> eventful journey up
> > to NYC, Montreal, and back to Denver.
> > If anyone has any better diagnoses, jump in. The air filter is
> within a couple of feet of the
> > ccrossover pipe and it was completely black when removed. Apart
> from a turbo failing, I
> > can't think of any other explanation. It definitely had fuel since
> the max fuel light was on
> > when it happened and it shot out lots of gray smoke upon start up.
> The only other thing
> > that could seem to cause a diesel to stop running is lack of
> compression, lack of timing, or
> > lack of air.
> >
> > Kerry
> > 82 FC 35
> > Denver
> > Singing the blues in WV (or should that be bluegrass?)
> >
>






[Non-text portions of this message have been removed]

[Gregory OConnor]

I think if it was an air issue you would see major black smoke out
the pipe. Why don't you run a 12 GA wire from a hot spot directly to
the Fuel shutoff (past the cockpit for removal on shut down). This
will rule out the fs power but not the FS solenoid.

If I was in MD waiting for UPS My bus would be towed bayside with
crab traps tied to the bumper and with in reach of Silverqueen corn
and Md cantaloupe
Gregory O'Connor
94ptRomolandCa

--- In WanderlodgeForum@yahoogroups.com, "davidkerryedwards"
wrote:
>
> This roadtrip is turning into a sequence of mechanical problems.
After we got the idler
> pulley repaired in MO, we made it to WV when the crossover pipe (a
second rate flexible
> pipe) failed. FMCA road service sent out a mechanic who removed
the broken end and re
> attached it. We got down the road 40 miles and it failed again,.
I reattached it myself and
> we limped into Cumberland MD on Saturday where we waited until this
morning(in a
> shopping mall parking lot) for an exhaust shop to open. Jim's
transmissionn and exhaust
> did an excellent quick job and we were on the road by 11am. A mile
down the road the
> engine quit suddenly at 60mph. Pulled over, restarted it and set
off again. this happened
> three times in 5 miles. I called FMCA road service again since it
was dangerous to drive
> since we lost power steering when the engine quit. Were towed to
Keyser WV ($431--buy
> road service!) where we are currently in a motel. The current
diagnosis is that when the
> crossover pipe failed it sooted up the air cleaner resulting in
very high vacuum in the
> intake which sucked down a rubber hose cutting off all air flow to
the engine and shutting
> it down. We're waiting for a new air filter to arrive by UPS
tomorrow. I had thought the
> turbo was failing and seizing up, so if this diagnosis is correct,
it's a much more simple
> fix. The diagnosis makes a fair amount of sense since the shut
down problems occured
> after the crossover pipe was properly fixed with a solid pipe which
would make the turbo
> operate more efficiently than the loosely attached prior repair.
> We hope to make it to DC sometime this summer and then have a less
eventful journey up
> to NYC, Montreal, and back to Denver.
> If anyone has any better diagnoses, jump in. The air filter is
within a couple of feet of the
> ccrossover pipe and it was completely black when removed. Apart
from a turbo failing, I
> can't think of any other explanation. It definitely had fuel since
the max fuel light was on
> when it happened and it shot out lots of gray smoke upon start up.
The only other thing
> that could seem to cause a diesel to stop running is lack of
compression, lack of timing, or
> lack of air.
>
> Kerry
> 82 FC 35
> Denver
> Singing the blues in WV (or should that be bluegrass?)
>

[davidkerryedwards]

I thought about the solenoid last night. I wasn't looking at the exhaust when
it shut down
but one time the max fuel light was on when it happened. However, it put out
clouds of
grey smoke when I started it up each time, which seems to indicate there was a
lot of fuel
in the engine. I'll buy a coil of wire this morning to try this out should the
air filter not
solve it. It is certainly acting as if I turned the key off.
As far as the general issue of putting o ut a lot of black smoke with a plugged
air filter, I
think the theory is that since the engine is turbocharged, the sucking effect of
the turbo is
overcoming the plugged filter to some degree, pulling thru a decent amount of
air until its
power collapses a rubber hose section of the air delivery pipe. Lucky for me (I
think), the
shop where it now sits had another truck come thru there this spring with
precisely the
same problem caused by a small underhood exhaust leak sooting up the air filter.

Kerry

--- In WanderlodgeForum@yahoogroups.com, "Gregory OConnor"
wrote:
>
> I think if it was an air issue you would see major black smoke out
> the pipe. Why don't you run a 12 GA wire from a hot spot directly to
> the Fuel shutoff (past the cockpit for removal on shut down). This
> will rule out the fs power but not the FS solenoid.
>
> If I was in MD waiting for UPS My bus would be towed bayside with
> crab traps tied to the bumper and with in reach of Silverqueen corn
> and Md cantaloupe
> Gregory O'Connor
> 94ptRomolandCa
>
> --- In WanderlodgeForum@yahoogroups.com, "davidkerryedwards"
> wrote:
> >
> > This roadtrip is turning into a sequence of mechanical problems.
> After we got the idler
> > pulley repaired in MO, we made it to WV when the crossover pipe (a
> second rate flexible
> > pipe) failed. FMCA road service sent out a mechanic who removed
> the broken end and re
> > attached it. We got down the road 40 miles and it failed again,.
> I reattached it myself and
> > we limped into Cumberland MD on Saturday where we waited until this
> morning(in a
> > shopping mall parking lot) for an exhaust shop to open. Jim's
> transmissionn and exhaust
> > did an excellent quick job and we were on the road by 11am. A mile
> down the road the
> > engine quit suddenly at 60mph. Pulled over, restarted it and set
> off again. this happened
> > three times in 5 miles. I called FMCA road service again since it
> was dangerous to drive
> > since we lost power steering when the engine quit. Were towed to
> Keyser WV ($431--buy
> > road service!) where we are currently in a motel. The current
> diagnosis is that when the
> > crossover pipe failed it sooted up the air cleaner resulting in
> very high vacuum in the
> > intake which sucked down a rubber hose cutting off all air flow to
> the engine and shutting
> > it down. We're waiting for a new air filter to arrive by UPS
> tomorrow. I had thought the
> > turbo was failing and seizing up, so if this diagnosis is correct,
> it's a much more simple
> > fix. The diagnosis makes a fair amount of sense since the shut
> down problems occured
> > after the crossover pipe was properly fixed with a solid pipe which
> would make the turbo
> > operate more efficiently than the loosely attached prior repair.
> > We hope to make it to DC sometime this summer and then have a less
> eventful journey up
> > to NYC, Montreal, and back to Denver.
> > If anyone has any better diagnoses, jump in. The air filter is
> within a couple of feet of the
> > ccrossover pipe and it was completely black when removed. Apart
> from a turbo failing, I
> > can't think of any other explanation. It definitely had fuel since
> the max fuel light was on
> > when it happened and it shot out lots of gray smoke upon start up.
> The only other thing
> > that could seem to cause a diesel to stop running is lack of
> compression, lack of timing, or
> > lack of air.
> >
> > Kerry
> > 82 FC 35
> > Denver
> > Singing the blues in WV (or should that be bluegrass?)
> >
>

[davidkerryedwards]

Chris:
I think it might be a good idea to start a data file which reported what
mechanical failures
have happened to forum members when on the road. It might show a pattern from
which
we could learn. In my case, I was not aware of any issues with the idler pulley
before we
left home. I had looked at the crossover pipe and thought a flexible pipe was
inappropriate and put it on the back burner for replacement. There was no
indication it
was about to fail, I just didn't like the idea of flexible pipe. I assumed the
cat dealer
installed it when the engine was replaced so I was also deferring to their
judgment.
The 3208 CAT service manual does provide recommended routine replacement times
for
various parts to avoid inconvenient failures. I'll have to check on the idler
pulley lifespan.
In may case, I'm not entirely sure what was replaced when a reman'd engine was
installed
25k ago.

Kerry
82 FC 35
Denver

--- In WanderlodgeForum@yahoogroups.com, Chris Reed wrote:
>
> Aside from belts and hoses, what else can I do as far as preventive
maintenance to make
sure I dont end up on the side of the road....I can't imagine going through what
Kerry is
now....what else should I be checking under this bus?
> Chris Reed
> 83 FC35 SB
> Plant City, FL
> Waiting for new/rebuild engine cooling fan....
>
> davidkerryedwards wrote:
> Crossover pipe takes the exhaust from one manifold over to join up
with the
exhaust from
> the other. In my case it takes the right exhaust over to the left side where
both power
the
> turbo. It broke on the left side right near the intake for the air cleaner
which is in front
of
> the left wheel. I had to drive it a couple of miles to an exit and it was
spewing huge
clouds
> of black smoke because the turbo was barely turning since the exhaust from
both sides
> was following the path of least resistance which was out of the broken pipe
instead of
thru
> the turbo. Without the turbo'd air it was way overfueled for the amount of air
it was
> getting.
> By the way, it is probably worth noting that the crossover pipe had probably
cracked
> before it broke resulting in less air and I had noticed the egt's were running
about 150
> degrees hotter than normal. They could get over 1200 degrees if I wasn't
careful on a
> steep hill. This tells me a richer or overfueled engine could have dangerous
EGT levels
> pretty easily.
>
> Kerry
>
> --- In WanderlodgeForum@yahoogroups.com, "Scott Forman" <sforman@> wrote:
> >
> > OK...dumb question...what/where is a "crossover pipe"?
> >
> > Scott Forman
> > 82 FC35RB
> > Memphis
> >
> > --- In WanderlodgeForum@yahoogroups.com, "davidkerryedwards"
> > wrote:
> > >
> > > This roadtrip is turning into a sequence of mechanical problems.
> > After we got the idler
> > > pulley repaired in MO, we made it to WV when the crossover pipe (a
> > second rate flexible
> > > pipe) failed. FMCA road service sent out a mechanic who removed
> > the broken end and re
> > > attached it. We got down the road 40 miles and it failed again,.
> > I reattached it myself and
> > > we limped into Cumberland MD on Saturday where we waited until this
> > morning(in a
> > > shopping mall parking lot) for an exhaust shop to open. Jim's
> > transmissionn and exhaust
> > > did an excellent quick job and we were on the road by 11am. A mile
> > down the road the
> > > engine quit suddenly at 60mph. Pulled over, restarted it and set
> > off again. this happened
> > > three times in 5 miles. I called FMCA road service again since it
> > was dangerous to drive
> > > since we lost power steering when the engine quit. Were towed to
> > Keyser WV ($431--buy
> > > road service!) where we are currently in a motel. The current
> > diagnosis is that when the
> > > crossover pipe failed it sooted up the air cleaner resulting in
> > very high vacuum in the
> > > intake which sucked down a rubber hose cutting off all air flow to
> > the engine and shutting
> > > it down. We're waiting for a new air filter to arrive by UPS
> > tomorrow. I had thought the
> > > turbo was failing and seizing up, so if this diagnosis is correct,
> > it's a much more simple
> > > fix. The diagnosis makes a fair amount of sense since the shut
> > down problems occured
> > > after the crossover pipe was properly fixed with a solid pipe which
> > would make the turbo
> > > operate more efficiently than the loosely attached prior repair.
> > > We hope to make it to DC sometime this summer and then have a less
> > eventful journey up
> > > to NYC, Montreal, and back to Denver.
> > > If anyone has any better diagnoses, jump in. The air filter is
> > within a couple of feet of the
> > > ccrossover pipe and it was completely black when removed. Apart
> > from a turbo failing, I
> > > can't think of any other explanation. It definitely had fuel since
> > the max fuel light was on
> > > when it happened and it shot out lots of gray smoke upon start up.
> > The only other thing
> > > that could seem to cause a diesel to stop running is lack of
> > compression, lack of timing, or
> > > lack of air.
> > >
> > > Kerry
> > > 82 FC 35
> > > Denver
> > > Singing the blues in WV (or should that be bluegrass?)
> > >
> >
>
>
>
>
>
>
> [Non-text portions of this message have been removed]
>

[Gregory OConnor]

Kerry, The Flexpipe you are talking about runs from engine part to
engine part and a solid pipe woud do. ( I am sure you know, just
wanted to point out to others) There is a need for flex pipe section
in the exhaust system between the bushing mounted diesel engine and
the solid frame mounted tail and stack pipes. the flex section
takes up the engine torque roll and frame twist and keeps the
manifolds, pipes and brackets from tweeking and cracking

I kept snapping pipes on a truck untill it was found that the flex
section was parallel to the torque roll and would not provide any
give. I added a flex on a section that was on an angle to the engine
axis to correct the problem.
Gregory O'Connor
94ptRomolandCa

--- In WanderlodgeForum@yahoogroups.com, "davidkerryedwards"
wrote:
>
I had looked at the crossover pipe and thought a flexible pipe was
> inappropriate and put it on the back burner for replacement. There
was no indication it
> was about to fail, I just didn't like the idea of flexible pipe. I
assumed the cat dealer
> installed it when the engine was replaced so I was also deferring
to their judgment.
>
> Kerry
> 82 FC 35
> Denver

[davidkerryedwards]

Yes, that piece of flex is important, although the 3208 does not
shake rattle and roll as much as the 5 cylinder in my Mercedes. I
think when the new engine was installed, the installer used flex
pipe because he didn't have access to an exhaust pipe bender.
Still waiting for the air filter to be delivered and it does not
look promising today. However, we are seeing places we had never
planned to see. We even saw the Great Race arrive in Cumberland on
Sunday. Very cool group of old cars.

Kerry

--- In WanderlodgeForum@yahoogroups.com, "Gregory OConnor"
wrote:
>
> Kerry, The Flexpipe you are talking about runs from engine part to
> engine part and a solid pipe woud do. ( I am sure you know, just
> wanted to point out to others) There is a need for flex pipe
section
> in the exhaust system between the bushing mounted diesel engine
and
> the solid frame mounted tail and stack pipes. the flex section
> takes up the engine torque roll and frame twist and keeps the
> manifolds, pipes and brackets from tweeking and cracking
>
> I kept snapping pipes on a truck untill it was found that the flex
> section was parallel to the torque roll and would not provide any
> give. I added a flex on a section that was on an angle to the
engine
> axis to correct the problem.
> Gregory O'Connor
> 94ptRomolandCa
>
> --- In WanderlodgeForum@yahoogroups.com, "davidkerryedwards"
> wrote:
> >
> I had looked at the crossover pipe and thought a flexible pipe was
> > inappropriate and put it on the back burner for replacement.
There
> was no indication it
> > was about to fail, I just didn't like the idea of flexible
pipe. I
> assumed the cat dealer
> > installed it when the engine was replaced so I was also
deferring
> to their judgment.
> >
> > Kerry
> > 82 FC 35
> > Denver
>

[Mike Hohnstein]

Keep in mind Kerry has an aftermarket turbo conversion applied to a NA 210 hp.
I suspect there is a fair bit of "custom" work done to the coach that
complicates maintenance issues when they arise.
Fresh properly adjusted belts,new hoses, proper cooling system ph level and a
clean fuel system are the best ways to stay off the side of the road.
Mike Hohnstein
Germantown, WI
83FC35
----- Original Message -----
From: Chris Reed
To: WanderlodgeForum@yahoogroups.com
Sent: Monday, June 26, 2006 10:31 PM
Subject: Re: [WanderlodgeForum] Re: Road trip blues


Aside from belts and hoses, what else can I do as far as preventive
maintenance to make sure I dont end up on the side of the road....I can't
imagine going through what Kerry is now....what else should I be checking under
this bus?
Chris Reed
83 FC35 SB
Plant City, FL
Waiting for new/rebuild engine cooling fan....

davidkerryedwards wrote:
Crossover pipe takes the exhaust from one manifold over to join up with the
exhaust from
the other. In my case it takes the right exhaust over to the left side where
both power the
turbo. It broke on the left side right near the intake for the air cleaner
which is in front of
the left wheel. I had to drive it a couple of miles to an exit and it was
spewing huge clouds
of black smoke because the turbo was barely turning since the exhaust from
both sides
was following the path of least resistance which was out of the broken pipe
instead of thru
the turbo. Without the turbo'd air it was way overfueled for the amount of air
it was
getting.
By the way, it is probably worth noting that the crossover pipe had probably
cracked
before it broke resulting in less air and I had noticed the egt's were running
about 150
degrees hotter than normal. They could get over 1200 degrees if I wasn't
careful on a
steep hill. This tells me a richer or overfueled engine could have dangerous
EGT levels
pretty easily.

Kerry

--- In WanderlodgeForum@yahoogroups.com, "Scott Forman" <sforman@...> wrote:
>
> OK...dumb question...what/where is a "crossover pipe"?
>
> Scott Forman
> 82 FC35RB
> Memphis
>
> --- In WanderlodgeForum@yahoogroups.com, "davidkerryedwards"
> wrote:
> >
> > This roadtrip is turning into a sequence of mechanical problems.
> After we got the idler
> > pulley repaired in MO, we made it to WV when the crossover pipe (a
> second rate flexible
> > pipe) failed. FMCA road service sent out a mechanic who removed
> the broken end and re
> > attached it. We got down the road 40 miles and it failed again,.
> I reattached it myself and
> > we limped into Cumberland MD on Saturday where we waited until this
> morning(in a
> > shopping mall parking lot) for an exhaust shop to open. Jim's
> transmissionn and exhaust
> > did an excellent quick job and we were on the road by 11am. A mile
> down the road the
> > engine quit suddenly at 60mph. Pulled over, restarted it and set
> off again. this happened
> > three times in 5 miles. I called FMCA road service again since it
> was dangerous to drive
> > since we lost power steering when the engine quit. Were towed to
> Keyser WV ($431--buy
> > road service!) where we are currently in a motel. The current
> diagnosis is that when the
> > crossover pipe failed it sooted up the air cleaner resulting in
> very high vacuum in the
> > intake which sucked down a rubber hose cutting off all air flow to
> the engine and shutting
> > it down. We're waiting for a new air filter to arrive by UPS
> tomorrow. I had thought the
> > turbo was failing and seizing up, so if this diagnosis is correct,
> it's a much more simple
> > fix. The diagnosis makes a fair amount of sense since the shut
> down problems occured
> > after the crossover pipe was properly fixed with a solid pipe which
> would make the turbo
> > operate more efficiently than the loosely attached prior repair.
> > We hope to make it to DC sometime this summer and then have a less
> eventful journey up
> > to NYC, Montreal, and back to Denver.
> > If anyone has any better diagnoses, jump in. The air filter is
> within a couple of feet of the
> > ccrossover pipe and it was completely black when removed. Apart
> from a turbo failing, I
> > can't think of any other explanation. It definitely had fuel since
> the max fuel light was on
> > when it happened and it shot out lots of gray smoke upon start up.
> The only other thing
> > that could seem to cause a diesel to stop running is lack of
> compression, lack of timing, or
> > lack of air.
> >
> > Kerry
> > 82 FC 35
> > Denver
> > Singing the blues in WV (or should that be bluegrass?)
> >
>

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