Re: "Piston Slap" How fearful should I be?? (archive)

I have a Metric Mechanic 2500HT engine that was just fuel injected. 9500 miles since new. CR is 10.5:1. It began making what sounded like valve noise except it went away above 2500RPM. We popped the head and found that #1 was "slapping" because the cylinder measured larger than the other three and the piston was actually smaller than the other three. The piston is scoured on four opposing spots.

My mechanic thinks we can sleeve the cylinder if we can get another matching piston from MM - which seems unlikely as to date they have been absolutely zero help! I guess my only other option would be new pistons. So: my questions O' Sensei's are these:

1. Should MM stand behind this?
2. Are there other solutions/options available to me?
3. What/whose pistons & rings should I get?
4. What ought this process cost?
5. Because this is a bored & stroked motor, will sleeving be a risky proposition regarding wall thickness?
Gentleman, I thank you in advance for any and all guidance and suggestions!!!!!!!!!!

Aside from all the good legal-related advice (and I say go get 'em!!) if you are forced to make the repairs yourself, you might consider having an after-market piston maker match one of the MM pistons. There are a number of fabricators who do this sort of work: JE is one I've heard good things about, Vinolia is one I've heard BAD things about...if MM used forged or cast pistons you will want ensure that this one will match the other 3. I don't think there's any reason to fear a properly done sleeving, and since this is an over-bored block, that's probably the best thing to do if you can find a *good* machinist to do it...but first, try to make MM eat this one, good luck!

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