Cracked injector nozzle tip
 

I have not seen this one on here yet. Started my truck and noticed exhaust white smoke. As I was driving the smoke got heavier and I started to loose power. Got the truck back home and checked for codes, none. Checked fuel pressure and it was okay, but at the low end. So, installed a new lift pump. Truck built fuel pressure, but would not start. Cracked injector lines to bleed system and had compression blowing out of #3 cylinder fuel line. Pulled injectors and #3 had a cracked tip. Replaced all the injectors, sounded like a good time to upgrade, and changed oil, #3 cylinder actually hydraulic locked with fuel. Since it was time to work on my own truck installed 3 piece exhaust manifold, 4 inch exhaust and adjusted valves. Runs great now.

Glad you got everything up and running. It's interesting how when one has time and starts one project, it turns into more projects.

Is this a common failure? I have seen quite a few cracked or broken off tips on power strokes and international dt466 and cracked injector bodies on duramax, but I have never seen this on a Cummins. It does show up in the Cummins factory repair manual.

Everything fails, it's a fact of life. Some things happen sooner than others. I wouldn't say it is common of these trucks though. The injection pressure is relatively low compared to the Common Rail engines. Higher the pressure, the stronger the material needs to be.