12 STEPS TO FAILURE ANALYSIS

Potential Warranty Status

Event
Problem Data Collection Requirements
• Design
Engine Part Is
1 Manufactured
• Material Errors Here Are WARRANTABLE
• Workmanship

• Rust/Nicks
2 Packaging And
Shipping
• Packaging Errors
Errors Here May or May Not Be WARRANTABLE
KEY: Inspect Before Installing -- Return Part P
• Labeling Errors
R
E
• Mis-Cataloged
(wrong part number
Errors Here May or May Not Be WARRANTABLE
KEY: Inspect Before Installing -- Return Part
F
Parts Ordering:
in catalog)
Data – Collection Required A
3 Shipment To
Customer • Ordered in Error
•
•
Reason for Overhaul
Vehicle & Engine Information
I
(catalog is misread)
• Number & Names of All Parts Purchased L
• Work Orders & Invoices
U
Errors Here Are NON-WARRANTABLE R
• Improper
Data – Collection Required
Work orders and invoices f or:
E
Machining • Block (bored/honed, • Connecting rods
Engine Hardware • Improper repairs to counterbores-
4 Preparation And Alignment main saddles-deck)
(rebushed,
reconditioned, new rod E
Machining • No Hardware • Cylinder heads bolts)
Inspection or
(resurfaced,
valves/guides replaced
• Camshaft (inspected, V
replaced)
Machining
•
or reground)
Crankshaft (polished,
• Manifolds E
(resurfaced, straight)
reground, straight)
N
Errors Here Are NON-WARRANTABLE
T
• Improper
Lubricants
Data – Collection Required S
Installation Of Work orders and invoices for ALL LABOR and
5 Parts And Engine
• Clearances
new/rebuilt PARTS for:
• Specifications
Assembly • Lubrication System
• Installation • Fuel System
• Air Induction
Procedures • Cooling System
System

• Improper Errors Here Are NON-WARRANTABLE

Lubricants Data – Collection Required
Engine Break-In • Improper Break- • Description of • Type of Oil Used
6 And On-Going In Engine Break-In (viscosity – API service
Operation • Improper PM • Description of PM classification)
Schedule Work (oil and filter • Miles/Hours/Years
• Operator Abuse change intervals, etc.) at Overhaul
 Method Action Data Collection Requirements
• Interview Data – Collection Required
Operator
Establish Reason • Miles/Hours/Years Since Last Overhaul
7 For Investigation
Regarding
• Detailed Description of Complaint and of
Engine
Engine Operation Prior to Failure
Performance

• Manometer
Data – Collection Required
Readings
8 Analysis And • Test Results
• Exhaust Check
Testing • Amount of Oil Used (for oil consumption failure)
• Compression
• Oil Analysis Report
Check

• Identify Related P
Engine System
Preparation For
Components and Data – Collection Required O
9
Tear Down
Related Wear
Surfaces to be
See Checklist on Bulletin SD-76
(Warranty Policy) S
Kept for
Inspection
T
F
• Determine If There A
Is Cause to File Claim
Tear Down, File • Arrange &
•
Parts & Data Submitted
Parts with Related Wear Surfaces
I
Number Parts for
10
Claim If
Appropriate
Failure Analysis • Claim Form (SD-63 for HD, SD-16 for Auto) L
• File Claim with • Related Work Orders and Invoices
Parts and Data from U
Steps 3-9
R
• Analyze Both
E
Failure Analysis Failure Analysis Returned
Parts and
11 By AE Clevite Service
Documentation
• Statement of Probable Cause of Failure
Engineering
from Steps 3-10
• Related Photos, Etc. E
V
• Interview E
Operator
12 Establish Reason
For Investigation
Regarding N
Engine
Performance T
S