Duramax Diesels Forum Truck of the Week
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Old 03-27-2019, 07:40 AM
Duramax_9505 Duramax_9505 is offline
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Default Callies Durastar Crankshaft Issues??

Recently had a 2015 LML come in with a "losing coolant, no leak concern". Determined to be a head gasket failure. After tear down, noticed stress cracks around the bowls of the pistons(no surprise there). Customer opted to tear down further for an engine rebuild with some upgraded parts to eliminate weak points. One of those upgrades being a Callies Durastar crankshaft. Fast forward 2 months and 30,000 miles, we now have an engine that has lost its thrust. It is my understanding that we are not the only company that has experienced these issues while using a Durastar crankshaft. In fact, after talking with 2 other individuals about their experience, they claimed their thrust washers were laying in the oil pan, intact! Currently, Callies has 3 crankshafts in their possession for testing from 2 other companies and probably a 4th one coming from us. So far, we have sent the torque converter back to Suncoast to be examined. However, we do not suspect this is the issue. It is the same converter that was linked to the stock engine for 7 months and nearly 120,000 miles. I will continue to keep this thread updated as we dig deeper into what is causing this issue.
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Last edited by Duramax_9505; 03-27-2019 at 07:51 AM.
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Old 03-27-2019, 07:55 AM
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You are far from the only one with issues itís not the converter.
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Old 03-27-2019, 07:56 AM
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Quote:
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You are far from the only one with issues itís not the converter.
What she said!
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Old 03-27-2019, 08:00 AM
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Sub'd
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Old 03-27-2019, 08:14 AM
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Well that sucks. So these are not a recommended option at this time?
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Old 03-27-2019, 08:45 AM
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What was the thrust clearance


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Old 03-27-2019, 09:03 AM
Duramax_9505 Duramax_9505 is offline
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During assembly, we had .0065" of clearance/endplay. That changed dramatically because the lower thrust washer was about to fall out and find its way into the oil pan. The upper one, well, let's just say it was happier when we put it in during assembly....
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Old 03-27-2019, 09:19 AM
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That is disappointing.
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Old 03-27-2019, 10:10 AM
Duramax racer 8 Duramax racer 8 is offline
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Very disappointing!!
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Old 03-27-2019, 10:25 AM
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Seems to be a Rockwell issue. Someones forgotten to rockwell test the hardness of their finished surfaces before sending them out the door..

There is no good reason a thrust bearing should ever wear out the crank. Guess everyone can stop searching for reasons that don't exist now. I was concerned enough to check my 2 ultras when we tore down both engines couple months back. So far those didn't seem to be gaining any end play.

Now only question is, all from same batch, or is it all to date??

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Old 03-27-2019, 10:36 AM
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Quote:
Originally Posted by kidturbo View Post
Seems to be a Rockwell issue. Someones forgotten to rockwell test the hardness of their finished surfaces before sending them out the door..

There is no good reason a thrust bearing should ever wear out the crank. Guess everyone can stop searching for reasons that don't exist now. I was concerned enough to check my 2 ultras when we tore down both engines couple months back. So far those didn't seem to be gaining any end play.

Now only question is, all from same batch, or is it all to date??

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This is the million dollar question!
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Old 03-27-2019, 11:29 AM
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Quote:
Originally Posted by Bdsankey View Post
This is the million dollar question!
Now is the opertunity to independently verify this one.

Suggest you find someone local who has a Rockwell testing tool. Likely someone who works with gears a lot. Have them compare the bearing harness to the the crank face surface. Along with a stock thrust bearing also.. I mean there is an odd chance ones in x bearing sets out there are harder than stock, but then this issue should also shown up on some stock crank rebuilds.

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Old 03-27-2019, 12:58 PM
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This is all I needed to read. Just used a callies durastar in my lml engine. Maybe it's time to send it down the road before it needs engine #4..lol
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Old 03-27-2019, 01:12 PM
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Quote:
Originally Posted by Blackmax123 View Post
This is all I needed to read. Just used a callies durastar in my lml engine. Maybe it's time to send it down the road before it needs engine #4..lol
Dont jump to conclusions to fast. Wait to see some data on failures. What type of application, hp level, clearances, and type of failure. Look at last year where 4 trucks lost Carrillos in a week.
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Old 03-27-2019, 01:48 PM
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What is causing the increased clearance, thrust wear or crank wear/deflection? What side of the thrust washer is seeing the wear?
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