12 STEPS TO FAILURE ANALYSIS

Event

Potential
Problem

Warranty Status
Data Collection Requirements
Errors Here Are WARRANTABLE

Engine Part Is
Manufactured

Design
Material
Workmanship

Packaging And
Shipping

Rust/Nicks
Packaging Errors
Labeling Errors

Mis-Cataloged

Parts Ordering:
Shipment To
Customer

Engine Hardware
Preparation And
Machining

Errors Here May or May Not Be WARRANTABLE

KEY: Inspect Before Installing -- Return Part

Errors Here May or May Not Be WARRANTABLE

KEY: Inspect Before Installing -- Return Part

(wrong part number

in catalog)

Ordered in Error
(catalog is misread)

Improper
Machining
Improper
Alignment
No Hardware
Inspection or
Machining

Errors Here Are NON-WARRANTABLE

Data Collection Required
Work orders and invoices f or:
Block (bored/honed,
Connecting rods

Installation Of
Parts And Engine
Assembly

Engine Break-In
And On-Going
Operation

Improper
Lubricants
Clearances
Specifications
Installation
Procedures

Improper
Lubricants
Improper BreakIn
Improper PM
Schedule
Operator Abuse

Data Collection Required

Reason for Overhaul
Vehicle & Engine Information
Number & Names of All Parts Purchased
Work Orders & Invoices

repairs to counterboresmain saddles-deck)

Cylinder heads
(resurfaced,
valves/guides replaced
or reground)
Crankshaft (polished,
reground, straight)

(rebushed,
reconditioned, new rod
bolts)
Camshaft (inspected,
replaced)

Manifolds
(resurfaced, straight)

Errors Here Are NON-WARRANTABLE

Data Collection Required
Work orders and invoices for ALL LABOR and
new/rebuilt PARTS for:
Lubrication System
Fuel System
Air Induction
Cooling System
System

Errors Here Are NON-WARRANTABLE

Data Collection Required
Description of
Type of Oil Used
(viscosity API service
Engine Break-In
classification)
Description of PM
Miles/Hours/Years
Work (oil and filter
at Overhaul
change intervals, etc.)

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Method

Action

Establish Reason
For Investigation

Analysis And
Testing

10

11

Preparation For
Tear Down

Tear Down, File

Claim If
Appropriate

Failure Analysis

Identify Related
Engine System
Components and
Related Wear
Surfaces to be
Kept for
Inspection
Determine If There

Arrange &
Number Parts for

File Claim with

Analyze Both
Parts and
Documentation
from Steps 3-10

By AE Clevite Service
Engineering

Establish Reason
For Investigation

Manometer
Readings
Exhaust Check
Compression
Check

12

Interview
Operator
Regarding
Engine
Performance

Data Collection Requirements

Parts and Data from

Steps 3-9

Interview
Operator
Regarding
Engine
Performance

Data Collection Required

Test Results
Amount of Oil Used (for oil consumption failure)
Oil Analysis Report

Data Collection Required

See Checklist on Bulletin SD-76
(Warranty Policy)

Is Cause to File Claim

Failure Analysis

Data Collection Required

Miles/Hours/Years Since Last Overhaul
Detailed Description of Complaint and of
Engine Operation Prior to Failure

Parts & Data Submitted

Parts with Related Wear Surfaces
Claim Form (SD-63 for HD, SD-16 for Auto)
Related Work Orders and Invoices

Failure Analysis Returned

Statement of Probable Cause of Failure
Related Photos, Etc.

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