Mackpro

Some techs just seal off both sides of the aftercooler and pressurize it by itself. I leave the aftercooler hose going to the intake manifold on that way you can check the intake manifold and the air compressor intake piping. Of course some of the intake and exhaust valves in the heads will be open and air will go past but with enough air pressure and a squrit bottle of soapy water you can find all kinds of leaks.

Your 2003 460HP is a CCRS ETECH engine which is a refined ETECH engine. The 460's have the wastegate turbo ( not to be confused with the ASET VGT turbo) , if you try to adjust the linkage and if the boost goes to high it will derate, we already tried this. Mack has some good Service bulletins on the CCRS wastgated turbo. We put alot of diaphragm kit on thoses turbos, its a bitch to get them set right and open when they are supposed to. Another place to look is the intake manifold gaskets, they usually blow out around #1 cylinder, Mack came out with some steer core gaskets to solve that problem.

One of my friends owns a early CV with a regular ETECH 400HP. His friend bought a CV as well with a 427HP. Now my buddy wants his 400 bumped up but like you he doesnt want to pull the cam and go through all that cost. So I called http://www.rochesterfuel.com/products/performance-mack-c-23_67.html and talked to them, they were very helpful and the guy I talked to really knew his stuff. (their injectors are alot cheaper than the Mack remans)I had my buddy give them a call but he hasn't decided what to do yet. Maybe a set of stage II injectors might be all you need. I also posted this, however it only applies to 427 CCRS engines, just in case anyone out there has a weak 427 CCRS. Here's a little tip for 427 CCRS engines with low power. We bought a fleet of 2002 CH's with this engine and all were low on boost pressure and power. We changed turbo and injectors, adjusted valves and did everything we could think of and still low turbo boost/ power. I called my buddy at our other Mack location and he said to replaced the injectors with 460P (736GB420M3X) ones and call Mack and have them turn on engine datafile 1MS5135. We did this and WOW what a difference, went from 22psi boost to 30 psi and this was after we put the old turbo back on. Just something I thought I would pass on to you guys. One of our customers bought one of these trucks and fixed it himself (I first put a 460HP datafile in it )but he had some bigger injectors buit and put on a 500HP Detroit Diesel 60 series turbo on and says it will scream, I have seen it in action and it seems to really get up and go.

Yes , there is a data file for the engine ECM that Mack turns on and the dealer programs it into the truck. Since your truck is a regular ETECH 355-380. I have some info for ya here in a bit.

Injector # 736GB415M2X (X means reman). Turbo # 631GC5173AMX (of course X means reman as well). The orignal 460 HP turbos were around $800-900 but the newer models have a super hard titanium impeller wheel. Most turbo shops can build the same thing with out the titanium wheel for a whole lot less. The camshaft has to come out and the cam gear pressed off and a off set keyway installed to retard the timing to prevent overheating in the summer. If you had a CL with the huge radiator you might get buy without the keyway change. We tried it with a RD and a CX and was ok in the winter but when the summer came they overheated.

Guess ya'll have had all girls?

Will do. And as far as kids go , sometimes I feel like I have "2 too many". The 12 hours in the Tahoe with 2 little ones coming back from Florida will make you wanna get your nuts cut. I'm 42 and we (wife is alot younger than me) might have one more if I was sure it was a girl. No more mean ass boys!

The injectors are $181 each and the Mack turbo is around $2100. I think a turbo shop could build one cheaper though. The labor to change the cam keyway is what is the killer. About 16+ hrs to change the keyway. If we were to do the whole conversion in our shop it would be over $5000.

A regular ETECH has a plastic fuel return hose coming off the front or back (mostly front) of the head going to the fuel pressure regulator on the passenger side of the block above the air compressor. The CCRS has no plastic line. The ASET AC and AI engines also dont have the line.

Yours was built on 1/16/2001 and is a regular ETECH engine , same as engine above, requring turbo, injectors and off set cam keyway. My hope was yours being built in 2001 was a CCRS style engine that requires no cam keyway change regardless of HP level. If it was a CCRS ETECH it would be cheaper to bump up due to no keyway change. As with all HP upgrades on ETECHs make sure you have the big vibration damper on, if not get one. You can tell if you got the big one by it almost touches the front motor mount horseshoe. On the small damper you can fit your fingers between the damper and mount.

Good to hear they could get it to act up. Keep us posted on how it turns out.

I was first thinking maybe low fuel pressure but probably not. I would go ahead and get the lastest software and data files for both ECM's (step 12B) and make sure your turbo has a *****5176***** in the part#. If it has a ****5171**** series turbo(2004 year model mostly) dont change the software. When we changed turbos from a 5171 to a 5176 the dealer has to change the engine software and data files. Most of the 5171 turbo are all gone/blew up. We have run across some customers who changed their own turbo to the new style and didn't get the software changed or the VGT calibrated and this caused all kinds of weird problems. With that said I would get the software/datafiles up to date, have the fuel pressure checked (80 psi)(if the supply pump has never been changed it might need it), have them check the boost pressure relief valve on top of the intake manifold (spring wears through the end of the housing), have them check for fault codes for the VGT/turbo and calibrate the VGT (must have 150 degree water temp) lastly have them unplug the connectors for the engine ECM and check for antifreeze in the harness plug. Thats all I can think of for now.

Oil is better than finding antifreeze in harness/ECM connection. We usually find antifreeze at the engine ECU and it can eat the terminal/pins out. Clean out the connections with electronic contact cleaner and recheck and clean every week for a month till it no longer showes up at the connection. Glad you found it.

I'll try to post a pic of the ECM wiring in the morning, We have a new PC hooked to our scanner, hope I can get it to work.

The Mack bulldog oil is made by Exxon Mobil and is good oil. Rotella is good oil also but I have seen changing over to Rotella after using another brand can cause some weird problems.

Wonder if it's factory? Being metal instead of plastic is good!

I only live just a couple miles from Show-Me's but never been there yet. A couple of our Techs went there today for lunch and said it "looked" nice.

Just noticed your grill doesn't say MACK on it? I see that grill on UPS trucks and other fleet trucks. Was it on there when you got it?

Hell, I'm heading to Motel 6 tommorow for lunch to see that!

I really dont like the looks of any hood/fender mirrors BUT I wouldn't drive a truck with a trailer without them. They are a must have for the long trailers you guy's pull. I do see them on dump trucks but I think you could get by without them. Maybe one day they will perfect a camera system with heads up display. We have a new GU813 just delivered (Rebublic Waste) with a roll off body that has cameras looking down both sides of the truck but you still have to look at that small display screen to see anything.

A MH with a E-9 500HP pulled in the bay next to Bigen's truck, If I could have swapped the engines between the two I think Bigen would be a happy man.

We are in western KY, we are a very small dealer with 2 other dealerships in surrounding states.

Wish I had a beter camera because it's a really sharp Rawhide CHN!

Bigen finally made it to the shop, Hope to get him up to snuff on the matainance and upgrades.

Is the fues panel red or black?