The Hidden Factory Bolt That's Destroying Truck Engines
About this episode
A major issue with the factory grid heater in 6.7 Cummins engines is causing catastrophic engine failures, prompting the introduction of a new intake horn and grid heater product by Fleece Performance. This episode dives into the design and testing process of the product, which aims to eliminate the failure point while maintaining cold start functionality. The hosts discuss the importance of reliability for truck owners who depend on their vehicles for work, and they share insights from their recent unveiling at PRI. Listeners will learn about the product's features, installation process, and pricing.
Amsoil
"And you guys had a new partnership, product unveiling with Amsoil and oil, which we chatted about."
Amsoil makes special engine oil that helps engines run smoother and last longer.
Amsoil is a company that produces synthetic lubricants and additives for engines, including diesel oils.
Ram Trucks 6.7L Cummins engine platform
"You know, specifically speaking to the six, seven engine platform, so 07.5 to 2024 ram trucks are all equipped with this grid heater."
This is a big diesel engine that powers many Ram trucks. It’s famous for pulling heavy loads and running smoothly.
The 6.7L Cummins is a heavy‑duty diesel engine used in Ram pickup trucks from 2007 to 2024, known for its torque and durability.
intake plate
"But we have been selling replacement intake plate for years for those people that want to get rid of, you know, the factory grid heater because it's such an issue."
The intake plate is a part of the engine that helps air get into the cylinders. It can have extra parts on it to keep the engine running smoothly.
The intake plate is a component of the engine’s air intake system that directs airflow into the combustion chambers. It often houses sensors or heating elements to improve performance and reliability.
factory grid heater
"Number one was, to John's point, it was eliminating this factory grid heater that commonly has the bolt that falls off and gets sucked into the engine."
A factory grid heater is a small device that keeps the air entering the engine cooler, which helps it run better. Sometimes its parts can break off and cause problems.
A factory grid heater is an aftermarket or OEM component installed in the intake system to keep air temperatures low, improving combustion efficiency. It can sometimes fail if a bolt loosens and falls into the engine.
heating elements
"That was number one, and all that John talked about some of the heating elements as we get into that."
Heating elements are small electric parts that warm the air going into the engine, helping it run smoother.
Heating elements are electrical components that warm the intake air to improve combustion and reduce engine knock. They can be integrated into grid heaters or separate units.
2024 Ram
"...2024 ram into a cold chamber, the whole truck."
A Ram is a big truck made by Ford. The 2024 Ram is the newest version that year.
The 2024 Ram refers to the 2024 model year of Ford’s full‑size pickup trucks, known for their large size and powerful engines.
intake manifold
"Maybe I'd just like the R&D side of it or the engineering side, but can you talk me through maybe the process for finding where the sweet spot was? Let's not say the cold weather kit, but just the standard where it's on the backside of the intake manifold."
Think of it as a pipe that sends the air (and sometimes fuel) to each part of the engine where it burns. It helps make sure every cylinder gets enough air.
The intake manifold is a component that distributes the air-fuel mixture from the throttle body to each cylinder in an engine. It is a key part of the intake system, ensuring balanced airflow.
temperature probe
"We had the intake instrumented with temp probe, so we could see how that actual unit heated up and where it was seeing the most heat."
It's a small sensor that tells you how hot something is inside the engine.
A temperature probe is a sensor that measures the temperature of air or fluid in an engine component, used to monitor and optimize performance.
2019 RAM 3500
"I had just gotten a 2019 3500 RAM and I driven it around for about six months."
A RAM 3500 is a big truck that can haul heavy loads. The 2019 model was the year it was made.
The 2019 RAM 3500 is a heavy‑duty pickup truck built by Ram Trucks, a division of Ford. It’s known for its large engine options and towing capability.
intake horn
"We were able to float test this intake horn on our flow bench here. We also did some chassis down in work just to compare."
The intake horn is a pipe that helps bring air into the engine. A better design can let more air in, which can make the car run faster.
An intake horn is a component that directs air from the throttle body or intake manifold into the engine’s cylinders. It can be tuned to improve airflow and boost performance.
flow bench
"We were able to float test this intake horn on our flow bench here. We also did some chassis down in work just to compare."
A flow bench is like a test machine that measures how much air can pass through parts of the car. It tells engineers if a part is good or needs improvement.
A flow bench is a laboratory setup used to measure the airflow through components like intake manifolds or horns. It helps engineers quantify how much air a part can move at different pressures.
cylinder head
"Your restrictor is the cylinder head. So our ability to flow air into the cylinder is directly related to the ability of the cylinder head to flow."
The cylinder head sits on top of the engine cylinders. It holds important parts like valves and spark plugs, and how well it works affects the car’s power.
The cylinder head is the top part of an engine that houses valves, spark plugs, and combustion chambers. Its design determines how efficiently air and fuel mix and combust.
Kershaw
"So if you're in the market, head on over to Kershaw.kaiusa.com."
Kershaw makes parts that can improve a car’s performance or appearance, like suspension upgrades or body kits. They’re popular among car enthusiasts who want to tweak their vehicles.
Kershaw is a manufacturer of aftermarket automotive parts, especially known for performance upgrades and accessories. Their products are often sold through specialty retailers and online stores.
cabin chassis
"Patrick, there's this will also cover cabin chassis."
The cabin chassis is the part of a car that holds everything inside – seats, steering wheel, and dashboard. It helps keep the car strong and safe.
The cabin chassis refers to the structural frame that supports the vehicle’s interior, including seats, dashboard, and passenger area. It is a critical component for safety and rigidity.
carburetor
"So we're working on pursuing the carburetor for this kit, which will have, you know, the coverage from 08 to 24."
Think of a carburetor as a mixer that blends air and gasoline so the engine can run smoothly.
A carburetor is a device that mixes air and fuel in the correct ratio before it enters the engine’s combustion chamber.
gasket
"But yeah, so what you're going to get in the kit is obviously you're going to get your intake, you're going to get your intake plate, gasket, set that goes with this kit."
Gaskets are like rubber or metal seals that keep fluids from leaking where parts touch each other.
A gasket is a seal that prevents leaks between two surfaces, such as the intake plate and the engine block.
map sensor plug
"We will have a map map sensor plug so that no matter which configuration your truck has, you can plug whichever hole you don't need to use."
It’s a plug that lets you add or take out a sensor that measures how much air is in the engine’s intake, useful for customizing performance.
A MAP sensor plug is an electrical connector that allows a manifold absolute pressure (MAP) sensor to be added or removed, enabling flexibility in engine tuning.
intake air temp extension harness
"And then there'll be intake air temp extension harness to again aid in every different configuration."
It’s a bundle of wires that lets you measure how hot the air entering the engine is, even if your car doesn’t have a built‑in sensor.
This harness is a set of wires that extends the intake air temperature sensor, allowing it to be used in various engine setups.
cold weather kit
"So, the only thing that would be separate if I wanted it would be the cold weather kit with the second heater, that's what I would, that's what I'd order separately if I if I needed it."
A cold weather kit is a bundle of parts that help a car stay warm and run better when it’s very cold outside, like extra heaters or better insulation.
A cold weather kit is a set of components added to a vehicle to improve performance and comfort in low temperatures, often including upgraded insulation, heated seats, or additional heating elements.
second heater
"So, the only thing that would be separate if I wanted it would be the cold weather kit with the second heater, that's what I would, that's what I'd order separately if I if I needed it."
A second heater is an extra device that keeps the car’s interior or engine warm when it’s very cold, so you don’t feel chilly inside.
The second heater refers to an additional heating unit installed in the vehicle, often used for cabin warmth or engine block heating during cold starts.
intake plenum
"I can't remember which diesel shop had posted a picture of one that there was truck in the shop and the nut had dropped into the intake, a plenum. And I don't remember exactly where it ended up..."
Think of the intake plenum as a big air box that splits the air coming into the engine so each cylinder gets enough air to burn fuel properly.
The intake plenum is a chamber in an engine’s air intake system that distributes the incoming air to each cylinder. It helps balance airflow and can affect engine performance and efficiency.
long block
""if you've purchased a long block from police, you know, we have parts that will help...""
A long block is basically a big engine that’s already put together except for the top part. It makes it easier to replace or upgrade an engine because you don’t have to build it from scratch.
A long block is a pre-assembled engine that includes the crankshaft, pistons, and cylinder heads but not the head gasket or valve train. It’s sold as a ready-to-install unit for rebuilding or upgrading engines.
intake system
""We also have an intake system to put on that cylinder head to protect your investment.""
The intake system is the part that brings air into the engine. A better or cleaner intake can help the car run smoother and faster.
An intake system directs air (and sometimes fuel) into the engine’s combustion chambers. Upgrading or repairing it can improve airflow, boost power, and protect the engine.
intake heater element
"a lot of people would just remove that factory intake heater element and they would just be stuck with a rough cold start or, you know, it wasn't very refined."
It’s a little heater that warms the air going into the engine so it starts better when it’s cold.
An intake heater element is a small electric component that warms the air entering the engine, improving cold‑start performance and reducing emissions.
rail
"I have to be removed. You're pulling the rail, you're pulling the existing grid heater out of there..."
A rail is a tube that carries fuel or air to the parts of the engine that need it. Think of it like a pipe that feeds the engine.
In automotive terms, a "rail" often refers to the fuel rail or vacuum rail that supplies fuel or air pressure to injectors or throttle bodies. It is a critical component in the engine’s fuel delivery system.
bolts
"So there's not a lot of extra cables and coils and bolts..."
Bolts are metal screws that hold parts of the car together, like a screw holding a picture frame to a wall.
Bolts are fasteners used to secure components together in a vehicle, such as attaching the intake manifold or mounting brackets.
coils
"So there's not a lot of extra cables and coils and bolts..."
Coils are parts that create the spark that lights the fuel in the engine, making it run.
Coils refer to ignition coils, which convert battery voltage into the high-voltage spark needed to ignite fuel in each cylinder of an internal combustion engine.
cables
"So there's not a lot of extra cables and coils and bolts..."
Cables are the wires that connect different parts of a car so they can talk to each other and work together.
Cables in automotive contexts are wiring harnesses that carry electrical signals and power between components, such as sensors, actuators, and control modules.
billet piece
"And go from a billet piece to a cast piece. Again, to kind of condense part numbers keep our kids uniform."
A billet piece is made from a solid chunk of metal that’s cut into the exact shape you need, making it very strong.
Billet refers to a solid block of metal that is machined into shape, resulting in a strong and precise component. Billet parts are often used for high-performance or custom applications.
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