Disappointed in my new 38r - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 73 (permalink) Old 02-25-2009, 03:22 AM Thread Starter
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Disappointed in my new 38r

I just installed a 38r on my 02. First of all the disassembly went fine, but I put the new one in and it would not line up with my up pipe flange so after fighting it for while I finally got it on and then I tightened the pedistal bolts and it pulled the up pipe flange away from the turbo. Now I've got a pretty good exhaust leak, and my egts did not drop as advertised. I can still take it 1500* no problem and all I've got is a tuner. Any suggestions????

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post #2 of 73 (permalink) Old 02-25-2009, 03:25 AM
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Re: Disappointed in my new 38r

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Originally Posted by DieselRangerKid View Post
I just installed a 38r on my 02. First of all the disassembly went fine, but I put the new one in and it would not line up with my up pipe flange so after fighting it for while I finally got it on and then I tightened the pedistal bolts and it pulled the up pipe flange away from the turbo. Now I've got a pretty good exhaust leak, and my egts did not drop as advertised. I can still take it 1500* no problem and all I've got is a tuner. Any suggestions????
a couple of things to consider here, the turbo is a direct replacement so the issues you have are with the installation not the turbo.
after you fix you exhaust leak then you can evaluate the performance.
BTW 1500 where and when?
and what tuner?
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post #3 of 73 (permalink) Old 02-25-2009, 03:39 AM Thread Starter
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Re: Disappointed in my new 38r

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a couple of things to consider here, the turbo is a direct replacement so the issues you have are with the installation not the turbo.
after you fix you exhaust leak then you can evaluate the performance.
BTW 1500 where and when?
and what tuner?
If it is direct replacement how come the flange didn't line up with the turbo? I'm not being a smarta#$, I'm just new to all of this
Also, we've got a small hill we race up maybe 2 or 3% grade that's where we do all our testing after upgrades. My tuner is a TS

2002 Ford F-250, 7.3, 6spd.
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post #4 of 73 (permalink) Old 02-25-2009, 03:40 AM
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Re: Disappointed in my new 38r

Fixing that leak is critical.

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post #5 of 73 (permalink) Old 02-25-2009, 03:44 AM
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Re: Disappointed in my new 38r

Loosen the up pipes at the manifold. They will pull the collector back when the turbo is removed from the tension.
So loosen them, then reconnect the turbo and collector. Make sure the dowel pin in the up pipe collector line up with the turbo, you'll feel it, and can't get a good fit w/o it. Once the collector and turbo are lined up, tighten, then get under the truck and tighten the up pipe/manifold connections.
I think the up pipe - manifold bolts/nuts are 10mm and 13mm.

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post #6 of 73 (permalink) Old 02-25-2009, 03:45 AM
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Re: Disappointed in my new 38r

Yup, sounds like installation issues more than turbo issues. I've never heard of one not fitting correctly.

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post #7 of 73 (permalink) Old 02-25-2009, 03:46 AM
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Re: Disappointed in my new 38r

It didn't line up because things expand and contract with heating and cooling. When you unbolted the stock turbo, the stock up-pipes shifted. It's darn near impossible to pull them back to where they need to be when they do this (which doesn't happen to everyone). If that rear flange didn't line up right, and the locater pin didn't seat and the clamp didn't pull both flanges tightly together, you've got a major exhaust leak and it's making the turbo a pig.

You need to loosen the rear clamp and loosen the bolts where the up-pipes attach to the exhaust manifolds so the whole thing moves around. Then position the flange on the back of the turbo so it lines up and sits flush...THEN put the clamp on and tighten it. If the bottom of the pipes has pulled up off the manifolds significantly to accomplish this, you might have to loosen the flanges where the pipes enter the collector behind the turbo (where the donuts are), manipulate the pipes so they seal tightly to the manifolds and then retighten the donut flanges.

Here's the catch...doing this will fix the leak you have now, but it could cause leaks at the donuts. This is worth a shot since it's free (except the labor), but you may need to do up-pipes and donuts or the bellowed up-pipes if you develop a leak there after getting things moved around.

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post #8 of 73 (permalink) Old 02-25-2009, 03:46 AM
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Re: Disappointed in my new 38r

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Originally Posted by DieselRangerKid View Post
If it is direct replacement how come the flange didn't line up with the turbo? I'm not being a smarta#$, I'm just new to all of this
Also, we've got a small hill we race up maybe 2 or 3% grade that's where we do all our testing after upgrades. My tuner is a TS
The turbo was in the right place as it can only fit one way, the up pipe flange on the other hand moved and caused your line up problem.
There is a male/female dowel pin for alignment purposes.
Have you determined where the leak is?
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post #9 of 73 (permalink) Old 02-25-2009, 03:47 AM
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Re: Disappointed in my new 38r

What I did was put the pedestal bolts in loosely, so the turbo would still move around on the pedestal. Then I tightened the V-band clamp from the collector to the turbo so it would pull the two together. After that, I tightened the pedestal bolts.
If that does not work, then loosen the up-pipes at the collector and manifolds if needed to adjust the collector location.

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post #10 of 73 (permalink) Old 02-25-2009, 03:54 AM Thread Starter
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Re: Disappointed in my new 38r

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Originally Posted by Powerstroke Racer View Post
The turbo was in the right place as it can only fit one way, the up pipe flange on the other hand moved and caused your line up problem.
There is a male/female dowel pin for alignment purposes.
Have you determined where the leak is?
The leak is right on top. Kinda like it pulled the flange away from the turbo when I tightened the pedistal bolts.

2002 Ford F-250, 7.3, 6spd.
1984 Ford Ranger Diesel - Top Secret
2007 Mazda 6
1952 GMC w/ Ford powertrain, 390, Top Loader 4spd.
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