I blew up my new DSS Engine...now what? - Ford Mustang Forum
 
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post #1 of 13 (permalink) Old 07-04-2013 Thread Starter
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I blew up my new DSS Engine...now what?

I am just sick to my stomach. I wanted a replacement engine for my 1998 4.6L 2V GT that I bought new and had 180K on the car. I ordered a short block from DSS last year and supplied them with the PI upgrade kit and some Comp Cams 262AH bump sticks and had it professionally installed last December.
The resultant engine made 325 flywheel horsepower with 340 ft-lbs. of torque. OMG I was a happy man!
Since that time I put 10K miles on the car and drove it as my daily driver through a Michigan winter. I never race it or even redline it. Last week, on the highway doing 80 mph, the engine just stopped - like I turned the key off. There were no sounds, no warnings, and no trouble codes. There was still 5 quarts of oil in the block and no evidence of overheating.
I had a mechanic check the engine and he said that the engine had seized...he could not turn the engine over with a wrench. I talked to the guys at DSS and they suggested looking at the inside of an oil filter. I did so and found a huge amount of fine metal with the consistency of mud! That pretty much confirms that the engine is shot.
I plan on removing the engine myself and shipping it off to DSS for a thorough analysis. I am hoping that some portions of the engine are salvageable...either the heads and cams of maybe even the piston assemblies...I just hope it is not a total loss.
I am intrigued though...what do you think might have happened?
Thanks, Jason
Caledonia, Michigan
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post #2 of 13 (permalink) Old 07-04-2013
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If the engine just seized up, sound like the oil pump stop working. You say the short block is about a year old and you let DSS assemble it so was there any kind of warranty?
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post #3 of 13 (permalink) Old 07-04-2013 Thread Starter
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Yes there is a warranty but it is for a limited time/mileage. I drove the car for 10,000 miles with no problems so I am past the warranty. Maybe when DSS takes a look at it they can see what happened, and if it still might be covered. I don't have a lot of hope though.
Jason
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post #4 of 13 (permalink) Old 07-04-2013
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If the engine seize of then you are looking at a complete rebuilt which mean the engine is going to have to be completely disassemble. Most likely the short block is going to be machine because of the pistons seizing up. Plus new rings, bolts, gaskets and labor. If DDS does not cover anything then this can be very expensive.
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post #5 of 13 (permalink) Old 07-04-2013
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Sorry to hear about that man. Hopefully DSS will be willing to work with you on the motor. Maybe they will be able to tell you what happened. Sounds like oil pump may have went out tho. I am doing a motor swap in my 98 as soon as I get back from my deployment. What pistons was you running in the motor? Was the PI heads stock or worked? I'm just curious what all you was running to put down those numbers at the flywheel.

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post #6 of 13 (permalink) Old 07-05-2013 Thread Starter
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I used a 4.6L short block from DSS, their forged piston assembly, stock PI heads, and Comp Cams 262AH camshafts. I also have a 75mm Accufab throttle body, full-length headers, and a Bassani dual exhaust witht he cats removed.
I thought the numbers were pretty nice too. The block was rated at 550 hp. The morning of the accident, I got a quote from Kenne Belle for a 2.1L supercharger. My target was 475 hp. That will have to wait now.
DSS has been awesome both with this incident and with the initial build last year. They are very knowledgable, very friendly, and great to work with. I am looking forward to dissecting the engine with them to find out what happened and to see what else I could have done to prevent it.
Jason
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post #7 of 13 (permalink) Old 07-05-2013
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Another nightmare come true. I'm sure that was some money.

Nothing better than factory smooth...
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post #8 of 13 (permalink) Old 07-05-2013
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What CC pistons was you using? Well I will say that if you have the money now that it would probably be a good idea to go forged. That way when you add a power adder you have larger limitations.

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post #9 of 13 (permalink) Old 07-05-2013
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Wow man that sucks. And just last night as I was daydreaming about built shortblocks it occurred to me that I had at least once heard of one of the few aftermarket builders having issues with their oil pumps, but couldn't remember who it was. Now I think I know...

Hopefully it's not a complete loss and some things can be machined back to life for ya. Keep us posted on how it all pans out and should DSS do anythimg nice or unexpected be sure to post about that as well. I understand that all warranties have limitations, but if it turns out to be something like a faulty oil pump it would be really cool of them to meet you halfway or something on resolving this. Of all of the things that could go wrong, your fault or not, there is really no good reason why an oil pump should fail especially that early into an engine's life.


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That sounds like you might want to brace for a total loss. With that much metal running through there... there are probably some things that can be saved, but when it comes to assembling and warrantying the new engine the builder will probably insist on new if there is any doubt since they will have to warranty it if it fails.

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Bummer man...I hope something can be salvaged for you. This is any Mustang owners nightmare,,keep us posted maybe we can all learn from what happened...Peace man and props to DSS for working with you...good luck!!

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post #12 of 13 (permalink) Old 07-06-2013 Thread Starter
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Thanks guys...hey I should say that I am extremely pleased with DSS. They built me a strong engine and their customer service was awesome as well. After all, the engine ran for a long time! I feel a little guilty wondering if I did something wrong or if I missed some symptoms somewhere. I am depending on DSS to do the autopsy.
I am disappointed but if I need to replace the short block I'll put in a 5.3 or 5.4 stroker. Power is a very addiciting thing! I also will do the work myself as I have the room and (now) the experience to do the mechanical work.
Thanks for your comments! And give DSS a call.

Jason
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Hey Jason there was no reason for that motor to blow up, this is pure poor engine building, assembly...few can do the mod motors correctly, I'd suspect the crank bearings were not installed properly. if you are lucky you can turn the crank and reuse everything else in a new block...
If I was you I'd sell what you have and get the Terminator, by the time you reassemble the motor, add boost and all the supporting mods you will have spent more than what the Termi costs out right

If you just have to keep the car, consider getting a whole Termi motor takeout, get the 6spd too if you can

Consider getting a "Teksid" block for your next rebuild/reassembly...being aluminum it's a great piece to have
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