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Lifter Failure? Report it here!

... Mine for example.. Never excessive idled, never pushed hard prior to warmed, fluids religiously, 5-40 valvo only oem filters...etc.
Cam and lifters replaced, tick returned after ~250mi. Now starting process of new engine. Tech believes casting is allowing excessive lifter rotation causing inconsistent roller to cam engagement.
Update: #6 cyl lifter bore had either a casting flaw or dmg from assembly (hard to say which)
They replaced the block (short) and she's back to normal and quiet.
 

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I have a 23 that started the ticking. It was every so often often at first. Only after the truck warned up. Could only hear it at idle. Then it started to happen more often, then I could start to hear it in the 1.5k-2.2k rpm range really loud with the window rolled down and the truck next to a wall that reflected the sound.

I went the flat tappet Hamilton route. The ticking is gone.

I've read a few people have the ticking come back going the wagler solid lifter conversion and no reports (again, that I've found) for anyone doing the Hamilton conversion.
Did you pay a shop for this, if so how much was labor?
 
Did you pay a shop for this, if so how much was labor?
The dealer did it for me, 3k labor. I didn't get pics of the bores they said they look alright and I trust the mechanic that did the work. I have all the hydraulic lifters and everything that came out though.
 
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I’m looking at buying a 2024 RAM Tradesman CCSB 4x4 Cummins tomorrow. Now I’m leary because of the lifter issue. Does the 5yr/100,000 mile power train warranty cover it?
 
I’m looking at buying a 2024 RAM Tradesman CCSB 4x4 Cummins tomorrow. Now I’m leary because of the lifter issue. Does the 5yr/100,000 mile power train warranty cover it?
Yes, power train covers engine internals. I wouldn’t sweat it though. Just keep up with the scheduled maintenance and you will be fine. IF, you do run into problems, that’s what your warranty is for.
 
Yes, power train covers engine internals. I wouldn’t sweat it though. Just keep up with the scheduled maintenance and you will be fine. IF, you do run into problems, that’s what your warranty is for.
Thank you
 
2023 with 19k miles and I have a tick at idle.

Rotella T6 5W-40 on my second oil change.
 
2021 2500, tuned/diet @ ~25K, noticed tick after oil change at ~35K, now have 41K miles and still ticking away.

Have used Rotella T6 5W40 for each oil change, generally ~7-10K intervals depending on time between last change.

Just changed the oil and sent sample to Blackstone for analysis - sample report came back with "normal" levels of metal (iron/steel) in spectral analysis, so does not appear to be significant damage yet to cam or lifters.

Wondering how quickly yall think I need to address the issue? - leaning towards the Hamilton flat tappet conversion. Can do some wrenching myself but would likely need to find a shop for this.
I've done the flat tappet conversion. My ticking started immediately after my first oil change around 9k. T6 5w40. Started at what seemed to be very random times. Never happened when cold but when warm it would be a random "tick" every few seconds or so. It was not ticking in a pattern, seemed random.
As the miles put on it got more and more frequent. I noticed I could start to hear a pattern to it now. And the ticking seemed to following along the rpm band. Ticking faster and more consistently when the rpms were higher.
I read tons of posts about the flat tappet vs the solid lifter conversion. I was going to do the solid lifter because it was slightly cheaper and I didn't find any negatives until I saw a post on another forum (unsure if I'm aloud to post links to other forums here) where one guy did the solid lifter conversion and he went months without tapping and then it returned. He then went flat tappet and it disappeared again.
So I decided to go straight to the flat tappet. No tapping immediately after the conversation. I changed my oil after 500 miles of breaking in the cam and new hardware to 15w40 oil as recommended and the tapping returned.
It is no where near as frequent and I can't find any specific pattern to it yet. I'm trying to see if it happens more often when cold or warmed up. It does not seem to be increasing in frequency any more so that's good. I'd say it's eliminated about 90-95 percent of the ticking. It doesn't tick at all when the rpms are higher (1.5-2.0k). So I do feel much more confident about it than the hydraulic lifters.
Time will tell. I'm just waiting for more data.
I know this isn't the type of thing you want hear when researching a big change to the motor. I know I wouldn't. But I would have liked to know if I'm the only guy or there that did the flat tappet conversion and still get a ticking. No one else seems to have posted the same.
Good luck on your decision.
 
surprised the
I've done the flat tappet conversion. My ticking started immediately after my first oil change around 9k. T6 5w40. Started at what seemed to be very random times. Never happened when cold but when warm it would be a random "tick" every few seconds or so. It was not ticking in a pattern, seemed random.
As the miles put on it got more and more frequent. I noticed I could start to hear a pattern to it now. And the ticking seemed to following along the rpm band. Ticking faster and more consistently when the rpms were higher.
I read tons of posts about the flat tappet vs the solid lifter conversion. I was going to do the solid lifter because it was slightly cheaper and I didn't find any negatives until I saw a post on another forum (unsure if I'm aloud to post links to other forums here) where one guy did the solid lifter conversion and he went months without tapping and then it returned. He then went flat tappet and it disappeared again.
So I decided to go straight to the flat tappet. No tapping immediately after the conversation. I changed my oil after 500 miles of breaking in the cam and new hardware to 15w40 oil as recommended and the tapping returned.
It is no where near as frequent and I can't find any specific pattern to it yet. I'm trying to see if it happens more often when cold or warmed up. It does not seem to be increasing in frequency any more so that's good. I'd say it's eliminated about 90-95 percent of the ticking. It doesn't tick at all when the rpms are higher (1.5-2.0k). So I do feel much more confident about it than the hydraulic lifters.
Time will tell. I'm just waiting for more data.
I know this isn't the type of thing you want hear when researching a big change to the motor. I know I wouldn't. But I would have liked to know if I'm the only guy or there that did the flat tappet conversion and still get a ticking. No one else seems to have posted the same.
Good luck on your decision.

You think it might be the oil used causing the noise? It’s a bit thicker than recommended on the stock engines.

By chance, what did you spend on the conversion?
 
surprised the


You think it might be the oil used causing the noise? It’s a bit thicker than recommended on the stock engines.

By chance, what did you spend on the conversion?
The 15w40 is what's recommended to run by Hamilton (I asked in a phone call to make sure) as well as the instructions for the flat tappet install.

I had the dealer install it. Ran 3k labor.

The 5w40 and 10w30 everyone believes the only reason these recommended was because of the hydraulic lifters which started to be installed in 2019+ years. Before that the recommended weight was 15w40.
 
I've done the flat tappet conversion. My ticking started immediately after my first oil change around 9k. T6 5w40. Started at what seemed to be very random times. Never happened when cold but when warm it would be a random "tick" every few seconds or so. It was not ticking in a pattern, seemed random.
As the miles put on it got more and more frequent. I noticed I could start to hear a pattern to it now. And the ticking seemed to following along the rpm band. Ticking faster and more consistently when the rpms were higher.
I read tons of posts about the flat tappet vs the solid lifter conversion. I was going to do the solid lifter because it was slightly cheaper and I didn't find any negatives until I saw a post on another forum (unsure if I'm aloud to post links to other forums here) where one guy did the solid lifter conversion and he went months without tapping and then it returned. He then went flat tappet and it disappeared again.
So I decided to go straight to the flat tappet. No tapping immediately after the conversation. I changed my oil after 500 miles of breaking in the cam and new hardware to 15w40 oil as recommended and the tapping returned.
It is no where near as frequent and I can't find any specific pattern to it yet. I'm trying to see if it happens more often when cold or warmed up. It does not seem to be increasing in frequency any more so that's good. I'd say it's eliminated about 90-95 percent of the ticking. It doesn't tick at all when the rpms are higher (1.5-2.0k). So I do feel much more confident about it than the hydraulic lifters.
Time will tell. I'm just waiting for more data.
I know this isn't the type of thing you want hear when researching a big change to the motor. I know I wouldn't. But I would have liked to know if I'm the only guy or there that did the flat tappet conversion and still get a ticking. No one else seems to have posted the same.
Good luck on your decision.

RE: links. We're generally not that insecure about links to other enthusiast sites as long as there's information that's technically beneficial to the membership and diesel community at large.
 
I've done the flat tappet conversion. My ticking started immediately after my first oil change around 9k. T6 5w40. Started at what seemed to be very random times. Never happened when cold but when warm it would be a random "tick" every few seconds or so. It was not ticking in a pattern, seemed random.
As the miles put on it got more and more frequent. I noticed I could start to hear a pattern to it now. And the ticking seemed to following along the rpm band. Ticking faster and more consistently when the rpms were higher.
I read tons of posts about the flat tappet vs the solid lifter conversion. I was going to do the solid lifter because it was slightly cheaper and I didn't find any negatives until I saw a post on another forum (unsure if I'm aloud to post links to other forums here) where one guy did the solid lifter conversion and he went months without tapping and then it returned. He then went flat tappet and it disappeared again.
So I decided to go straight to the flat tappet. No tapping immediately after the conversation. I changed my oil after 500 miles of breaking in the cam and new hardware to 15w40 oil as recommended and the tapping returned.
It is no where near as frequent and I can't find any specific pattern to it yet. I'm trying to see if it happens more often when cold or warmed up. It does not seem to be increasing in frequency any more so that's good. I'd say it's eliminated about 90-95 percent of the ticking. It doesn't tick at all when the rpms are higher (1.5-2.0k). So I do feel much more confident about it than the hydraulic lifters.
Time will tell. I'm just waiting for more data.
I know this isn't the type of thing you want hear when researching a big change to the motor. I know I wouldn't. But I would have liked to know if I'm the only guy or there that did the flat tappet conversion and still get a ticking. No one else seems to have posted the same.
Good luck on your decision.
Thanks for posting this to share with everyone. You are the first one to post about tapping after the flat tappet conversion. I think there are a couple of members on here who went the solid lifter route and the tapping returned for them. At least yours is 95% better, at this point I wonder if you have an issue with the lifter bores in your block. I believe I have read on here there have been a few cases in which the lifter bores were out of tolerance.
 
Thanks for posting this to share with everyone. You are the first one to post about tapping after the flat tappet conversion. I think there are a couple of members on here who went the solid lifter route and the tapping returned for them. At least yours is 95% better, at this point I wonder if you have an issue with the lifter bores in your block. I believe I have read on here there have been a few cases in which the lifter bores were out of tolerance.
It's possible about the bores. The guy that did the conversion has been working on the Cummins engine since their 1st Gen in Dodge. He claimed that the engine "looked good" minus the cam. But didn't mention anything about the bores.

I'll keep this post updated if anything changes on my end. I'm hopeful because it's been about 5k miles and the ticking hasn't gotten any worse. It's stayed random and infrequent.
 
2019+ LIFTER FAILURE:

I’ve had quite a lot of requests to document these.
If you have had a lifter failure, I’d like to record your trucks information. The goal here is to see how many of these failures have occurred, as well as document basic data surrounding the failure. You can open the form to view it prior to filling it out, that way you can see if there’s information you need to collect prior to filling it out and submitting it. I’ll be using this reporting form to gather data. I will transpose the information onto a publicly viewable spreadsheet as the forms get submitted. Any questions or feedback please comment below.

You can find the form at this link:

You can view the spreadsheet results here:
Lifter Failure Spreadsheet
mbarber84,

Well this is new…too me. Thank you for the spread sheet. If I may, I suggest putting the last eight of the vin on the spread sheet. This may allow for some to get ahead of the problem if they are falling within or near a number sequence.

R/
Randy
 
Well y'all it's been a bit since I've been on here but I wanted to give an update as of today...

Still no truck, it sits at the dealership on its 3rd set of lifters in the span of time since I last posted. FCA send an engineer out to diagnose the truck and report back. They have denied a buy back and asked for a cash demand. " A demand for cash. You keep the vehicle and they give you some cash for your troubles. You’d have to sign a release and would not be able to make any more lemon law claims. Warranty stays in tact per its original terms. And financing is unchanged. You continue with payments per your loan terms." I am currently getting an attorney involved and attempting the arbitration route as well, whichever is quicker. I need a work vehicle lmao. It's been a total of 49 days without my truck all together.
 
Well y'all it's been a bit since I've been on here but I wanted to give an update as of today...

Still no truck, it sits at the dealership on its 3rd set of lifters in the span of time since I last posted. FCA send an engineer out to diagnose the truck and report back. They have denied a buy back and asked for a cash demand. " A demand for cash. You keep the vehicle and they give you some cash for your troubles. You’d have to sign a release and would not be able to make any more lemon law claims. Warranty stays in tact per its original terms. And financing is unchanged. You continue with payments per your loan terms." I am currently getting an attorney involved and attempting the arbitration route as well, whichever is quicker. I need a work vehicle lmao. It's been a total of 49 days without my truck all together.
What did their engineers find?
 
So, according to the dealership the engineer is stumped on why the problem keeps occurring and is requesting another engineer come down here and assess it. Which said could be an additional 2-3 weeks.

Once I get something in writing I'll let you know what was found/said.. unfortunately doesn't seem like much was done
 
I recently noticed a random tick at idle but it increases with RPM, I suspect it could be a lifter. The sound gets louder with RPM, it’s very noticeable from 1400-1500rpm but at idle it ticks worse when the AC is on which is odd to me and it’s not the compressor clutch. It’s a 22 with 38k miles, so I tried taking it to the dealer and had no luck, apparently they couldn’t hear it. Now I’m trying to take it to a different dealer but they are 8 weeks out. My question is should I still be running the truck or am I going to make things worse. Also, I can post a link with a video of the sound.
 
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