The Ultimate Guide to Diesel Engine Crankshaft Repair

Introduction 

Having issues with your diesel engine crankshaft? Not starting or running rough? Don't despair - with some basic knowledge of diesel engine crankshaft repair, you can get your vehicle back on the road. This ultimate guide will walk you through everything you need to know, from understanding common problems to DIY repairs and professional engine crankshaft repair options. Whether you have an aging farm truck or a modern heavy equipment engine, we've got you covered.

Understanding Diesel Engine Crankshaft Problems

The crankshaft is arguably the most important component inside a diesel engine. It converts the linear motion of the pistons into rotational motion that allows the vehicle to move. Common crankshaft problems in diesel engines include:

- Worn main or rod bearings from lack of lubrication 

- Damaged or broken crankshaft from overheating/overloading

- Bent crank from collision or thrown rod

- Cracked or broken crank nose

Symptoms of a bad diesel crankshaft include hard starting, rough idle, loss of power, loud knocking noises from inside the engine, and smoke coming from the tailpipe. If ignored, complete failure can occur.

Performing Overhauling of Diesel Engine 

When engine crankshaft damage is severe, a complete diesel engine overhaul may be necessary. This involves disassembling the entire engine, inspecting components, repairing/replacing worn parts, installing the crankshaft, and finally reassembling everything to factory specifications. 

Full diesel engine overhauling requires special tools and expertise to complete properly. The costs in parts and labor can quickly exceed the value of an older vehicle. However, for modern heavy equipment or trucks, a full diesel engine overhaul to replace the crankshaft makes economic sense to extend the machine's lifespan.

DIY Repairs: Metal Stitching Cast Iron Crankshafts 

For moderately damaged cast iron crankshafts on older engines, DIY repairs may be possible using metal stitching techniques to repair cracks and regrind bearing surfaces. This involves drilling holes at either end of a crack, then threaded steel wire is inserted to essentially "stitch" the crankshaft back together. Afterwards, glazing is removed from bearing surfaces using an abrasive stone to expose fresh iron.  

Metal stitching successfully repairs some - but not all - severely damaged crankshafts. Deep cracks into oil galleries, large chunks missing from crank throws, overheating damage, or extensively warped cranks may have weakened the structural integrity too far for repairs. Always have crankshafts checked by a professional before installing them if DIY metal stitching is performed. 

Professional Crankshaft Repair Services

For professional-quality diesel engine crankshaft repair or replacement, the team at MPA Power Projects follows OEM specifications to machine, weld, heat treat, straighten, rifle drill, and polish cranks to strict tolerances. For cracked cranks, their proprietary pulse-arc welding achieves deeper penetration into cast iron while minimizing heat distortion. Highly trained technicians and the latest CNC tooling enables MPA Power Projects to handle virtually any diesel crankshaft repair job. 

Additional services like dynamic crankshaft balancing, oil seal replacement, vibration damper rebuilding, injection pump timing, and engine tuning gives vehicle owners a true engine crankshaft "refresh" - often to better than new condition and durability. MPA Power Projects services all makes and models of foreign and domestic diesel engines for heavy duty equipment, trucks, generators, tractors, pumps, oilfield applications and more. 

While the cost of professional diesel engine crankshaft repair services may seem high at first, it allows the engine to reliably operate longer than installing inferior quality rebuilt cranks that fail prematurely. Partnering with a professional shop like MPA Power Projects provides peace of mind from a quality job done right the first time.

When to Choose Engine Crankshaft Repair Over Replacement 

So when does crankshaft replacement make more economic sense over attempting repair? Here are a few general guidelines:

• If no usable core crankshaft exists to start with. 

• When excessive main/rod journal wear exceeds the maximum allowable spec

• If thrust faces are heavily worn or damaged.

• Excessive heat damage has weakened crank integrity. 

• Deep surface cracks into oil galleries found (depending on location).

• Repair costs exceed 60-75% of a quality new or remanufactured crankshaft.

While minor issues can be repaired, excessive wear and tear typically makes replacement a smarter choice than attempting to salvage a worn-out crankshaft. Each situation differs, so consult a professional diesel mechanic to explore your options.

Also Read: Why Choose MPA Power for Your Diesel Engine Overhaul Services?

Diesel Crankshaft Replacement Considerations

Here are some additional factors to consider when replacing a worn diesel engine crankshaft:

• OEM vs Aftermarket Replacement: OEM cranks must adhere to strict OEM specifications for durability but come at a premium cost. Quality aftermarket cranks can save money with warranties against early failure. Discount cranks don't live long.

• New vs Remanufactured: New cranks are generally preferred for longevity, but factory remanufactured to OEM specs offers a much lower price point. Evaluation of the supplier’s quality control standards helps determine if a remanned crankshaft can reliably deliver many more years of service life. 

• Enhanced Design: Many diesel crankshaft manufacturers now use improved designs over original equipment for added strength. For instance, upgrading keyway slots to eliminate fractures, enhanced oil galleries to increase lubrication, or upgrading to billet steel rather than cast iron cranks. Improved materials and engineering affords better longevity.

Having the engine crankshaft - the heart of your diesel engine - repaired or replaced by industry professionals ensures your vehicle or equipment keeps running for years down the road. For professional diesel crankshaft repair and replacement services, contact the team at MPA Power Projects today. Their full service capabilities delivers increased performance, longevity, and reliability.

Conclusion

Repairing or replacing a worn diesel engine crankshaft keeps your vehicle or equipment investment from an untimely demise. This ultimate guide provided key information to understand common crankshaft failure points, overhauling considerations, DIY metal stitching techniques, when to choose repair over replacement, and professional diesel crankshaft service options through MPA Power Projects. Major engine components like the crankshaft require precise machining and specifications best left to those with the proper tools, training, and experience. By leveraging professional repair and replacement services when needed, your diesel powered vehicles and equipment will stay on the job through longer duty life cycles - saving you significant time and money over the long run.