Cost vs. Replace: Making Smart Decisions in Crankshaft Repair

cost vs replace in crankshaft Repair

The crankshaft is also referred to as the ‘heart of it as it is its backbone’. It transforms the direct line kinetic force exerted by the pistons into the rotary force that moves an Automobile. Over time, wear and tear or sudden damage can lead to a critical question: In what circumstances do you need a crankshaft repair, and in which circumstances is it more sensible to opt for a crankshaft renewal?

Every decision has implications that may include the economic effects such as cost and time requirements of the product and further basic decisions as the reliability factor in the future. In this blog, you will discover what goes into a decision and how one is made.

Understanding Crankshaft Damage Types

To make the above choice, one needs to distinguish between a repair and replacement, which is done after determining the severity of the problem. 

 

Crankshaft damage occurs in several varieties, with each type bearing its effect on the engine performance and the likelihood of the crankshaft repair.

Categories of Crankshaft Damage

  1. Scoring and Grooving
    • Caused by insufficient lubrication or contaminated oil.
    • Visible as scratches or grooves on the journal surfaces.

  2. Cracks and Fractures
    • Resulting from high stress, overheating, or excessive loads.
    • Often undetectable without non-destructive testing like magnetic particle inspection.

  3. Bent Crankshaft
    • Caused by improper handling, accidents, or imbalanced loads.
    • This leads to misalignment and affects engine performance.

  4. Worn-Out Journals
    • Occur due to prolonged usage and lead to uneven wear patterns.

Recognizing the type of damage is relevant because it determines skills and scope of repairs and opportunities arising out of replacement.

Assessment Criteria

  • Visual Inspection: Check for visible wear, scoring, or cracks.

  • Micrometres and Gauges: Measure journal diameters to identify excessive wear.

  • Non-Destructive Testing (NDT): Use techniques like dye penetrant or ultrasonic testing to detect cracks.

Cost Analysis of Repair Options

Crankshaft repairs are still seen more as an ideal option than crankshaft replacement, mostly if the problem is not very severe enough to cause serious damages. 

 

But again, all the extra costs must be considered to establish if repairing is the most economical solution.

Labor Costs

The labour cost is determined by the degree of the damage and the difficulty level in executing the work. For example, precision grinding may be needed in resurfacing journals, which leads to the cost.

Parts and Materials

Bearing Replacement: Bearing are tired and usually replaced during the service.

 

Grinding Tools and Equipment: Precision involves using high-quality equipment; hence, grinding contributes to costs.

 

Depending on the equipment, there are two options to consider in terms of downtime: planned or unplanned.

 

Spending lots of time on Crankshaft Repairing is customary, which always translates to much time wasted on the equipment in question. This can result in:

 

  • Lost productivity.
  • Extra rental expenditure by clients for tangible resources is required occasionally.

Equipment Downtime Considerations

Repairing a crankshaft often means extended downtime for the equipment. This can result in:

  • Lost productivity.
  • Additional rental costs for temporary machinery.

Replacement Considerations

However, in some circumstances, repairing a crankshaft might seem more advantageous than replacing one, but in specific cases, replacement cannot be avoided. 

 

People may decide to replace rather than repair based on the above factors, such as the level of damage done, previous repairs, and the advantages of installing a new component.

Get in Touch Today!

Ready to take the next step? Contact us today, and let’s make it happen. Our team is just a message away!

New vs. Remanufactured Options

1. New Crankshaft:

  • It is supplied with warranties and guarantees long-term performance.
  • It’s more expensive upfront.

2. Remanufactured Crankshaft:

  • Cost-effective and eco-friendly.
  • May have limited warranties or shorter lifespans.

Installation Costs

Replacing a crankshaft involves significant labor costs, including:

 

  • Engine disassembly.
  • Fresh installation and readjustment.

 

According to Lanterncredit, if the crankshaft needs replacing, repairing a car as essential as the one described above can cost as much as $2,500. 

 

However, occasionally, if only minimal damage is done to the part, it is possible to weld the crankshaft instead of replacing it. It was found, on average, based on parts and labour costs, that the repair cost was $270.

Warranty Implications

  • Repairs may not come with extensive warranties.

  • New crankshafts often include warranties, reducing future risks.

Decision-Making Framework

Both repair and replacement are options for assessing damages, repairs, costs and the future gains that will result from the two options. 

The consequences of using crankshafts with minor damage, including light scoring or grooving, may be repaired and serviced at a much lower cost than a complete change. 

 

Repairs are appropriate, mainly when limited funds or an influx of business necessitates an instanter business proposal.

When Repair Makes Sense?

  • Minimal Damage: Things such as a few points or scratch marks.

  • Budget Constraints: An essential point is that it is less expensive to repair rather than replace, which should be noted here.

Downtime Sensitivity: The benefit of doing repairs is that it takes even less time than when the crankshaft has to be obtained from the marketplace.

When is Replacement Necessary?

  • Severe Damage: Crankshafts that have cracks, fractures or bent ones.

  • Repeated Failures: In the case where the crankshaft has been worked on several times with the output gradually decreasing.

  • Long-Term ROI: Substitutes ensure higher reliability and longer life cycles.

ROI Calculations

  • Initial Cost: Evaluate the options where one involves repairing, and analyze whether the repair costs are higher that the costs of replacing the object.

  • Maintenance Costs: Evaluate the risk of recurrence of the problem after work has been done.

  • Resale Value: A new crankshaft is also associated with improved equipment resale value.

Case Studies and Examples

Case Study 1: Surface Wear Repair

A truck crankshaft was found to have just slight signs of journal wear resulting from low lubrication. Fixation entailed journal grinding and bearing replacement, for which the company spent $500. An actual crankshaft new one would have to go for about $2,000. It also allowed performance to be restored at a reasonable cost.

Case Study 2: Severe Fracture Replacement

A crankshaft in a marine engine received a deep crack. The repair process was considered dangerous and expensive. Replacing it with a remanufactured crankshaft would cost $4,000, but this came with a warranty of 2 years.

Conclusion: Making Smart Decisions

When deciding whether to fix or replace a crankshaft, it all boils down to the degree of the damage, the cost estimate, and the owner’s goal or vision. Crankshaft repair can be used for minor problems, whereas replacements are the most effective procedure in cases when the crankshaft has suffered heavy damage or when the vehicle’s reliability is the core value.

Pro Tip: Always seek the advice of your auto mechanic or engineering expert to check on the crankshaft status. They can always assist in making the best decision that is financially manageable.

MPA Power Project Provides the repair and overhaul of engines, compressor shaft grinding, insitu grinding of crankshaft, turbine rotor shaft grinding. A marine engine room, the turbine hall of a power station and a large compressor house are typical working environments of MPA Power Projects Pvt. Ltd. We specialize in in-situ machining and repairs for Marine and Industrial plants.

FAQs

1. How much does crankshaft repair typically cost?
Depending on the damage, repair costs can range from $300 to $1,000.

2. Is it better to replace or repair a crankshaft?
It depends on the damage. Minor wear can be repaired, but severe issues often require replacement.

3. Can remanufactured crankshafts be trusted?
Yes, as long as they come from a reputable source and include a warranty.

Share:

Facebook
Twitter
Pinterest
LinkedIn
No Comments

Post A Comment

Open chat