03 Cummins 5.9L Hard Knock Diagnosis

2nd gen 2003 Dodge with 264,000 miles, completely stock engine and transmission, developed hard knock at highway speed. Performed basic tests to identify the problem.

[@jwcathey33]

I had no idea an injector could cause a noise like that. Very good video.

[@user-hk9jb8xd1m]

OMG my stomach has been in knots for a couple days thinking about the cost. As many have commented here, you are our hero. Thank you for making this video, would love to donate to your cause of choice. Thank you again. Jerry R So Cal California 07 Mega Cab 5.9 4x4 smarty Jr, Banks horn, AFE exhaust manifold 5” straight exhaust.

[@GodBoxWagon]

I can't tell you how much I appreciate you making this video. I had no idea it sounded like somebody was inside of my engine hitting it with a hammer really fast. I treated it like a hot soak in the injectors with Lucas main line that in through the fuel filter. You saved my arse brother thank you so much

[@rickbowles1569]

Joel your my hero I just finished replacing my injectors the knock is gone she runs better, I just finished a 20 mile test run she runs and sounds fantastic. I was just getting ready to pull the hood off and start pulling the engine, but I just couldn't believe it was a blown engine so a got back on the KZbin and ran across your video went out to test it and it was injector so thanks again and my wallet thanks you. Rick

[@heaistevenhoko1845]

Thanks for the sharing this great video. It certainly has led me to resolving my diesel knocking issue with my Mazda BT50 WL engine.

[@imnew2nm324]

Highest quality DIY on KZbin. Thank you.

[@joseiniguez1583]

Same knocking noise is on my truck I can’t believe is so simple thank you my friend you save me a lot of money

[@flattops]

I've driven commercial trucks for 21 years and followed their rules, fix only whats broken. I know others recommmend replacing all, assuming if one is bad the others are soon to follow. If they were difficult to access then I would replace all, it makes sense. These are easy access and easy to replace, so just one at a time.

[@BuggysTowJam]

I don't blame you there, i don't know if yours cost the same but they're from 2 to 400 around here for oem and your suppose to replace the cup and quill at the same time on my 2012 6.7 cummins the cups are $50 each and haven't got price on quill yet. If it ain't broke don't fix it. And they're easy to get too except number 6 being so far under the firewall.

[@nickhowden7302]

Just wanted to say thanks my truck has been down for over a month now 06 5.9 and I had the same issue and I used your method and it worked for me and helped me verify witch injector is bad

[@terrywaters6186]

Good to know! FWIW I started to have an injector issue on my 04 5.9 with 200k miles. I ran a couple tanks of fuel with Stanadyne Injector cleaner through it and the problem seems to be gone and it's running smoother than it has in a long time. Prior to that I ran Power Service in my fuel most of the time at the minimum rate. I had no idea an injector could sound like a rod knock.

[@Powers4213]

this is the best video ever uploaded on to this website. I don't own a truck, but I want to now that I know how to solve this problem. thank you so much, sir.

[@DdDd-ec8ew]

Thanks for taking the time to put this on it helped finding something to try before spending $$ at the shop

[@gregaccess7265]

I have a random noise which comes and goes which sounded just like what you encountered. Thanks for taking the time to document.

[@hemilove]

Great video I liked how you presented the problem and showed the steps on how to check. 👍

[@johnhalter445]

Great diagnosis on her, mine on my 04 are still testing good but have been thinking hard about replacing them before they fail. Close to 200,000 on it with tuner. Been a great truck

[@a13oan]

Top video, I have a little European diesel which cut out while driving and made an exact same noise. I feared the worse but after watching this i checked my injectors and voila!!! car cured. Really informative video!!!

[@billthompson9595]

Great video. I have a 5.9 as well. Glad I am still able to learn something new each day. On hearing your engine I cringed thinking bearing bottom end. I was wrong..Thank you

[@jaygallagher8064]

Thanks for the step by step video. Very well done.

[@lucioolivas5515]

Joel thanks for the video my 05 did the same thing yesterday so have some where I can go from . Thank you again

[@KirklandPrime]

Hey @Joel Harrison my '02 5.9 just threw the first injector as well. Your step by step video was perfect, thank you for your time! Semper Fi Edit: liked the video, hope to see more!

[@grumpyraytv7778]

No wonder why I wanted a Cummins out of the Marine Corps, all of my brothers are getting them haha. Semper Fi

[@CoM-cf2yq]

Great video and big help with troubleshooting... thanks for posted.... The opening felt like I was at Commander’s Call ha..

[@Massachusettsmorons]

I liked the video and would definitely watch many more of yours very helpful informative and professional

[@shreducation4818]

Great video especially for your first one. Having a similar problem so I’m gonna try this out. Thanks!

[@zackbemister4310]

Very helpful video! thanks, now i know a knock isn't always a bad bearing! injectors shot!

[@wtrlvr241]

Wow, your video is awesome!, I just had this same issue happen today and I will be checking my injectors tomorrow, my truck sounds the exact same so this gives me hope

[@kevinklepp9526]

Wow thanks for the great tips on trouble shooting going to be very helpful if I run into the same trouble

[@aaronjencson3714]

Great video big help! Thank you for your service RTLW

[@patrickholcomb9628]

Thank you sir for your time and video and thank you for your service sir.

[@flattops]

Far greater men than I have served. I owe it to them and it was an honor to do so.

[@gregknutsen673]

Thank U 4 your service brother

[@gregknutsen673]

Thanks for your help I have the same noise & have an injector on the way

[@MrPajamaman40]

Thank you Joel for the video. I never heard a bad injector b4. Now I know

[@davebailey8093]

Hey Brother, I just had the exact same thing happen and thanks to your video I'm on top of the issue now 👍

[@georgewashington1106]

I'm all in at "if you don't like it, I don't care". Awesome.

[@SJJsolomonSJJ]

You sure as hell got me thinking my injector/s are shot. I thought I may have had a bad bearing but the thing about it is it doesn’t knock all the time, only when the truck warms up. I know a bearing would knock all the time and not some time. Thanks again🫡

[@thelifeofwindowlickermike6643]

All information is awesome thanks for you efforts keep going

[@josegonzales4297]

Thank you brother that was very helpful very very helpful you don't know how much I appreciate you God bless you bro I thought it was an engine that was done I checked as you said it was fuel injector number thank you so much 👍🏼👏🏼👏🏼👏🏼💪🏼😊

[@hornstrum]

Thank you so much!! Your video IS appreciated!! I have 2003 5.9 24V longbed 2WD dually 229K miles; yesterday truck was racked and I was underneath with the guy showing me blowby out bottom hose drain and crankshaft endplay!? Mine is knocking but not anything like yours! On acceleration I have sensed what I think is wrist pins but probably isn't knowing what I know now. I was told needed rear main journal bearing & seal; mine is slightly seaping. Months ago my MPG dropped by 10; previously she did 19.1 real MPG. I don't have money and this RAM ordeal is devastating quaqmire because it jeopardizes our lifestyle and survivability (18,500 lbs 5th wheel trailer). If my engine dies about all I can do is junk it. Can't afford to redo motor, front end needs full redo (i redid all front end 4 years ago), dashboard defrost control don't work (that's $1000 dealer job) I can't work on my truck where i live (then there is THAT) new oil, motor starts and runs like a clock, i drive 1800 to 2500 rpm most of time regardless of gear. Apparently my RAM does NOT have knock sensor, am bewildered what to do. I bought mine with 209K miles and it came with new injectors so 30,000 miles i surely could use injector(s) and/or maintenance. I run Lucas in the fuel every other tank or further. Friend told me to drain 2 quarts oil and put 2 quarts Lucas oil treatment in and sell the truck! Jeez the b.s. lives forever! Thank You again for your video. I appreciate You!!

[@justinbarnes5498]

Fantastic video! Really appreciate you taking the time to help the community. By the way, I can tell you are military trained, and given my experience in the aviation community, my thinking is you may be a pilot? Many thanks again, I am doing some in-depth study on my 2003 5.9 and came across your content. All the best.

[@jfubele]

Thanks Joel! I really appreciate this video!

[@jsmedbond]

Excellent video!!! Waiting for the follow up.

[@Koflers]

Thanks for the great diagnostic video.

[@austinmars4294]

Thank you for the video man,helped a lot!

[@superspeed2956]

beautiful! same problem on a dump truck im working on already doing the injectors because of a miss! Old Mechanic thought it was a rod knock or the crank bearing giving out hopefully it will be as simple as an injector!

[@troy1672]

Thanks for the video. Mine has been making a similar noise although not as bad and the knock doesn't sound like metal. But it is definitely something associated with that area. I thought maybe valve rockers but this might be something simple to check first. No codes but that doesn't mean there is no issue. I did have to replace one of the injectors recently. Maybe I got another one getting ready to go on me. Thanks for the information.

[@raadtoma6175]

Thanks for your video. It did help me to know the problem.

[@christiantejedor8676]

Great video in DIY diagnostics

[@1easystreakingzabu]

great information! thank you for doing this video!

[@asowens29]

Wow, this is really helpful!

[@mikecude4167]

I had a very mild injector knock, like yours, just barely noticeable though, with a mild bit of white smoke...paid dodge $150 to diagnose, and the said all injectors were good, but needed a valve adjust. Took it home, adjusted the valves, didn't go away. Then I replaced all the injectors (#6 is a bear to change) and that fixed the issue along with a ton of gained power.

[@flattops]

I don't use a shop for anything unless there is expensive equipment required. I can't recommend anyone. These are not overly complicated engines. You can fix just about anything yourself, with minor help from dealers regarding computer resets and updates.

[@toddehling2319]

I never used a shop either but ever since I got hit on my motorcycle by an SUV my body is getting worse. I can't stand very long anymore so unfortunately I had to have a shop pick up my 03 Ram for the same noise as yours. I really hate to think what this is gonna cost me with being on disability the money is thin if ya know what I mean. I'll have to check in on getting one of those truck creepers that you lay on while working in the engine bay. I'll just have to save up for it that way I can do everything myself again. Thanks for the informative video and Thank you for your service!!!

[@goodolrudy5621]

Best video ever, very good and thank you 👍👍

[@rickbowles1569]

This same noise happened to my 2003 5.9 was at auto parts came out fired it up and there was my knock so truck has been sitting since April tomorrow I'll do the same test, thank you so much for video will reply back if that was the problem. Rick

[@eaguerrero1]

Great video sir! Thank you!

[@wadebond7679]

I recently purchased my first Cummins...its a 1989 d350..brought it home changed the fuel filter and oil. A few days later noticed the same sound as yours but it goes away after the engine warms up...hope mine is as simple to fix as yours...thanks!!!

[@willricaboats]

Thanks for taking the time to show your diagnostic technique , have a bit different problem but i think is injector related and this helped. Did you only replace the injector on #1 ? or did you decide to replace the entire set .

[@DirectCurrent4u]

Great informative video! Thanks for sharing...👍

[@flattops]

Number 1 injector failed. The sound was most likely from deadheading the fuel to an injector the wouldn't open. Replacing the injector solved the issue.

[@txtomcath1533]

Joel Harrison Great info glad to hear that fixed it. Thanks for the lesson 👍

[@BAVICK89]

Does deadheading mean the fuel is getting to the injector but not going through it???

[@nebttaffom8404]

So did you replace it and found it went away? Did you damage anything due to the injector being bad?

[@gunz_n_bikes171]

Joel Harrison the lift rod should be tight and snug with the valve push rod arm theres a lock nut unscrew it and lower it til it is flush with the push rod then tighten the living hell out of the lock nut should be fine unless you have other problems such as a bent or warn out push rod then replace those trust me it’s unhealthy for the truck and it will save you alot more in the long run too

[@jazzsounds8159]

Joel do you know of a good shop for a 99 Cummins 3500. I'm in Denver.

[@davidcruz-ku2zb]

awesome video , great info

[@joshuafitforbattle8999]

Great video. Well done

[@donrives136]

Well done Sir, conventional common sense troubleshooting.

[@user-bd1wq8wq6u]

Excellent video thank you

[@trappingnut41mt]

Thank you for video helps a lot .

[@njgl2010]

Thanks man you just fixed my problem

[@hddm3]

Great video. Keep it up. Thanks

[@Jeremyandroid]

Thanks so much. I have same issue on Early 04. Except with a ton of white smoke. So going to narrow things down after Christmas

[@Bill-in2fo]

Jeremy Strain what did you figure out with your truck? I’m on the side of the road rn with the same issue you described

[@javiergonzalez-us5is]

@@Bill-in2fo I have the same problem. What did you find?

[@swabbster3]

Great video!

[@TRSnikeZ]

Amazing video

[@austinmars4294]

Keep the vids up man

[@joelbriseno4785]

thanks for the information

[@rogerbrewer7770]

Thanks for the info! Semper fi

[@ertreeservice9558]

Great video thank you!

[@1022lr]

Great video! And thank you for your service!

[@failingdisciple938]

Great video!! Thnx!

[@flattops]

One injector in 280k miles. Seems fair.

[@Land_Cruiser_40]

If one fails, aren't all the injectors at the end of the line? Cheers

[@kevinmd77]

Thank you for the video Joel. Very informative. Hey I was just curious on how I would go about troubleshooting my injectors? Do I need a special tool, gauge etc? I have a “valve tap” like noise going on with my 6.7 but only under load or heavy acceleration. The gentleman I got it from said he replaced the injectors but not the lines if that makes any sense? It also starts hard and after it’s warmed up if you shut it off and try to start it back up it’s even harder to start. I’m still kind of a noob with these trucks so I’m just searching for a direction to go with it to try and troubleshoot the issue myself (maybe known problems to look for etc). Any help would be greatly appreciated!

[@stevenbean9706]

Have this identical rap in my motor on passenger side . Found it with my mechanic stethoscope of all things.

[@iamme2617]

thanks i have exactly the same problem on my vw 2.0tdi

[@daltonhatten5204]

Thank you very much. I have a 06 Cummins that has the same knock and it started doing it after I put injector cleaner in the fuel. Injectors are getting tested. But after this video I believe injectors are my problem

[@robertofl86]

Hi harry i have the same sound after replace my 6 injector and sound come front cyl 1 you can feel on the injector fuel line i gonna try you videos two see if the sound go away i am worry that sonthing is bad on the engine thanks for you video help a lot

[@BuggysTowJam]

I have my recently purchased 2012 6.7 cummins in the shop, just had head gasket done. Previous owner used it as work truck for his business. Radiator had a hole and he kept adding water. A in doing so ran it hot several times. Put radiator and water pump in it but it was to late. Shop sent head off to Napa they shaved .005 of an inch off it. Thursday night the mechanic got it put back together and tried starting the truck. Killed the starter. So Friday gets new starter. Truck fires up and sounds good for about 5 seconds. Next several hours truck won't start. Mechanics cracking fuel lines and getting alot of air and foam. He kept cracking the lines over and over for about 2 hours. He then shot some ether into intake and truck fires up, but is knocking it's ass off. And i mean it was knocking loud, amplify your sound by 100 and that's what i was hearing. The truck wouldn't stay running unless he spritzed it with ether. Which i wasn't happy about. Heard to many horror stories the intense heat melting a cylinder with ether. Anyway the mechanic tells me it's an injector. This mechanic is the go to in our area for diesel engines. He's got a very good reputation that he's built. I just hope he's right with it being the injector. Because the knock was so loud. And i drove the truck the day i had it towed up to his shop. I'll know tomorrow if he's right that's when the new $400 injector from dodge will be in. Oh and my truck has 196k miles on it. Was bone stock, and i wanted it put back that way and he said my egr was shot. So he offered to delete it for free for taking so long working on the truck. I just had to buy a tuner and cold air intake.

[@dalton1583]

Good catch

[@michaelbrewer1474]

Odd question. The motor looks great, what oil do you run and how often do you change it? Thank you for your service sir!

[@justinadams1936]

Very helpful it helped me solve my injector issue on my 03" also 👍🏻

[@mikehall4851]

I just uploaded a video of my engines knocking sound as well. Identical to this just wasn't as far gone as his. An injector knock from what I've seen always come from the drive/common rail side.

[@cosmo12334]

I have a 2005 and it sounds just like your truck with the knocking. I will pull the wires to test it tomorrow. Thanks for the video.

[@jeffreyboone1688]

Description says 2nd gen, it's a 3rd gen. Semper Fi!

[@fabienfriolet9083]

My 99 just sarted to knock like that... I'll give you some newif it was that.. Thank for the tips man handyman love those video haha keep on the good advise👌

[@mikegonzalez9971]

Hey bud. I was wondering how your 5.9 doing? Any updates?

[@pepperschannel444]

Where's the update ??

[@xaviergonzalez5145]

Thank you!!

[@josefeliciano21]

Thank you boss

[@ianp2009]

Thank you

[@stevenacord7642]

Sweet 👍 man thanks

[@bernhard8540]

see im having the same sound but theres no power loss or anything and its been like that for a year the guy i bought it from said it had the knock for about a year and he just barely drove it so he never messed with it... i got a heck of a deal on the truck even if i had to buy an engine so win win with no rust but thanks for this video it helped me alot

[@mickpee1468]

Same here. Just bought a turbo diesel Mitsubishi Canter truck. Same knocking noise, still has power. Got it cheap as well.

[@curtis73463]

Yes sir.. i believe it i had a bad miss so tried to limp it to a shop then it started banging hard like bent rod i had a buddy pull me with a half ton just a few miles and i put it in gear while being pulled and there wasn't a knock so knew it had to be an injector problem which it was at first then pressured up the fuel pump and that was trashed to. Put all new injectors in and a new injection pump and it runs like new again.

[@1Defran]

Great diagnosis brother, my 6.7 is making the exact same sound. Did you happen to take notice if it knocked louder and faster when on the throttle? Mine does knock faster and louder when on the throttle. I have watched a few videos and the guys are not stating whether or on not if it was. I have a feeling mine is a bearing.

[@cubanken]

Semper Fi Bro

[@matthewwolfe2699]

I have a 2006 dodge Cummins 5.9 this video really helps me because I had old injectors and my truck didn't make this kind of noise before I just replaced all 6 injectors the truck fired right up however I got the same knock and didn't know where it would be I'm gonna try this and see if it helps thanks

[@Austin2276]

what was issue

[@joemandarino9818]

When you did the kill test and loosened one nut on each injector did you disconnect the batteries or anything before loosing them?

[@Resistolitin]

Pretty good for first youtube video.

[@scottdowney4318]

A reasonable assumption the injector is it seems over fueling the cylinder (leaking fuel) or firing too soon. There is also the fact that not hooked up, it is not firing, so combustion pressure is not developing in that cylinder, some rod knocks will go away when the cylinder does not fire.

[@hollywoodboggie]

Thanks!

[@billyjones9045]

Sounded like money blowing in the wind and me banging my head on my windshield