I know... It's been a while but I just got around to pulling the head today...

 

I'm guessing there is no cylinder damage. But, you may need a new/rebuilt head. One piston, rings, rod and bearings for that one cylinder and you should be good.

 

Take that damaged head to a machine shop that rebuilds heads and get their opinion if it can be salvaged.

 

The damage to the cyl head is not good obviously and I see at least one crack in the exhaust valve seat. So you need to have the cyl head checked out for obvious reasons. The head gasket is not a factory gasket so the heads have been off before and that is probably how that roll pin found its way into the combustion chamber as debris. You need a new piston as well. Head may be repairable. But for sure the exhaust valve seat is damaged and needs to be replaced. Good luck.

 

The cylinder looks very good. No damage can be seen, just normal wear for about 113k miles. I can actually still faintly see the factory cross hatch from when it was new.

That's exactly what I am doing. They will let me know if it can be saved.

The head gaskets are factory. I purchased this truck brand new in December of 2006. I can assure you that it has never had the head off before. Nothing on the engine was replaced except for spark plugs, thermostat, and alternator.

I have a idea of how the roll pin got there. Many miles ago, I replaced the sparkplugs at the same time as I replaced the alternator. I pulled the COP's and changed the plugs, then changed out the alternator before reinstalling the COP. While changing the alternator, I was using a Milwaukee cordless impact and I also had a 3/8" drive universal joint between the impact and the socket. The universal joint broke under the force of the impact. Pieces went flying around from the universal joint. Now, I'm pretty sure the roll pin from the universal joint settled down the spark plug well and sat for many miles without problems next to the spark plug, but I never knew it was there....fast forward to this go around of changing spark plugs...I pulled the spark plug and the roll pin fell in the cylinder, but i didn't know it. Replaced the spark plugs and fired it up....BANG BANG BANG BANG!!!.......AH ****!

 

Crazy story on possible source of the roll pin.

Just goes to show you can never be sure until you recover every piece of any part or tool that goes kaboom in or near the engine bay

 

Dang! Talk about BAD LUCK! That really sucks!

 

Because of the # of problems reported with Lightnings blowing out plugs, I was always paranoid when changing the plugs. I got into the habit of using a Shop-Vac with a small piece of tubing to clean out each spark plug well before I tried to pull the plugs. I followed the vacuum with several blasts of air from the compressor to try and blow out any remaining sand, etc.

I'm not saying it would have helped in this instance but the vacuum just might have grabbed the pin. It was always amazing to me how much crap got down in there, even with the COPs snugly seated.

Good luck with the repair and thanks for sharing. Great detective work on figuring out the source of the pin. Not everyone would be so willing to share the truth behind the problem. I applaud your honesty.

 

Drove that sucker straight in it did! This is the first time I saw this thread ... fascinating ... and I am sad it happened.

Glad you seem to have it on the road to recovery though! Lots of hope for others who have these things happen.

In a way, you were very lucky way back then when that universal blew up. They make HD Universals for use with impact drivers, those with roll pins are hand tools only .... but then you likely knew that right after that one went "kablewey"!

Watchingfor the updates I am ........ Good Luck!
Got me thinking of a follow up with vacuum again after the blast and maybe a small magnet .... or inspection with small camera probe? That could happen to any of these engines with the deep wells.
As do I! Anyone can learn from this!