Turbocharger rebuilding and pedistal info - PowerStrokeNation : Ford Powerstroke Diesel Forum
 
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post #1 of 23 (permalink) Old 08-14-2010, 10:47 PM Thread Starter
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Turbocharger rebuilding and pedistal info

The Electric Fuel Pump Conversion has been working really well. But after getting the truck up and running I noticed I had an oil leak. After some investigating I found out the pedestal, where the turbo was welded is leaking...






So I took the turbo back off so that the pedestal could be welded again. While the turbo was off I noticed that the turbo had some slop in it. Wierd because when I had the turbo off the last time there wasn't hardly any slop at all. After talking with some people it was decided that things should be ok. I just happened to talk to the wrong people.

So I had it welded hoping that the leak would go away. I learned that once cast aluminum has had oil run through it can be a real pain to weld.

Got the pedestal back, put the truck back together and although it was much better. The leak was still there. So instead of trying the welding again I decided to order a pedestal with the EBPV delete so no welding will be required. I also ordered a turbo rebuild kit in hopes that I would be able to get rid of the slop. Beans here on the board supplied the pedestal and rebuild kit.

The rebuild kit comes with a lot more than I thought it did. Here's the picture from the Beans Diesel Performance site...



Here's what you actually get...











Everything needed to rebuild the turbo for $125.00 unless you need a new compressor wheel or housing or...

1997 F350 with a few mods and over 392,000 miles.

National Spring Leafs, E-Fuel, John Woods Transmission, Detroit Lockers Front & Rear, 4:56 Gears, Michelin XML Tires, Custom RSK...

Lots of pictures
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post #2 of 23 (permalink) Old 08-14-2010, 10:48 PM Thread Starter
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Re: Turbo Woes

Pulled off the turbo off to rebuild it and replace the pedestal. The leak remains...






I still have the leak at the down pipe too...




The freeze plug where I removed the flap for the EBPV is leak free at least...



Looks like it got pretty hot too.

1997 F350 with a few mods and over 392,000 miles.

National Spring Leafs, E-Fuel, John Woods Transmission, Detroit Lockers Front & Rear, 4:56 Gears, Michelin XML Tires, Custom RSK...

Lots of pictures
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post #3 of 23 (permalink) Old 08-14-2010, 10:48 PM Thread Starter
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Re: Turbo Woes

Check out the gap between the fins and the housing on top and bottom...





Check Out My Little Movie



Crummy pictures but it's not to hard to see the "modified" fins...








Housing not looking so good...








Compressor Wheel came off easy enough...








I don't know what caused this. But it was pretty deep. Maybe a balancing thing?




1997 F350 with a few mods and over 392,000 miles.

National Spring Leafs, E-Fuel, John Woods Transmission, Detroit Lockers Front & Rear, 4:56 Gears, Michelin XML Tires, Custom RSK...

Lots of pictures
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post #4 of 23 (permalink) Old 08-14-2010, 10:51 PM Thread Starter
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Re: Turbo Woes

The turbo is pretty much toast but by taking it apart I have a better understanding about what makes it operate.

The 4 bolts that hold the turbine housing didn't want to come out...








Ended up using a strategically placed chisel to get the two pieces apart...




Look what I found on the inside…’








But the turbine housing looks pretty good other than the messed up bolt hole...






The shaft is ruined...




The center section looks good...




There is a rubber seal around the outside diameter...







It's pretty amazing that after 310,000 miles that rubber seal is still elastic.

1997 F350 with a few mods and over 392,000 miles.

National Spring Leafs, E-Fuel, John Woods Transmission, Detroit Lockers Front & Rear, 4:56 Gears, Michelin XML Tires, Custom RSK...

Lots of pictures
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post #5 of 23 (permalink) Old 08-14-2010, 10:51 PM Thread Starter
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Re: Turbo Woes

They say it's important that if you are attempting to rebuild the turbo that this piece in the center gets installed in the same orientation that it comes out...




To get it out just push it out from the opposite side...









After the two pieces came out more damage was found...






The Old...



New...





More wear...






Here's the modified pedestal...






Up against the non-EBPV pedestal from Beans...




1997 F350 with a few mods and over 392,000 miles.

National Spring Leafs, E-Fuel, John Woods Transmission, Detroit Lockers Front & Rear, 4:56 Gears, Michelin XML Tires, Custom RSK...

Lots of pictures
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post #6 of 23 (permalink) Old 08-14-2010, 10:52 PM Thread Starter
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Re: Turbo Woes

So on Monday morning I gather all of my parts and head on over to Action Turbo in Santee. Tom got a good laugh looking at my parts. He explained that with the damage shown it wasn't from a lack of oil. It was from contaminates in the oil. I had originally thought that when the pedestal was welded that maybe one of the ports was welded slightly shut.

So Tom hooked me up with one of his rebuilt turbos. At $495 I thought it was well worth it...












All I needed to do was file this edge down so the extension and swivel socket would fit on the bolt...






This really speeds up the installation of the turbo back onto the truck.


Add a rubber band to the bolt heads so the threaded part of the bolt does not knock the orings out of place on top of the block...




Turbo bolted down...




I lost the seal coming out of the compressor housing ...




So off to Ford and $7.00 later I have a new one...




All bolted up and ready to go again...


1997 F350 with a few mods and over 392,000 miles.

National Spring Leafs, E-Fuel, John Woods Transmission, Detroit Lockers Front & Rear, 4:56 Gears, Michelin XML Tires, Custom RSK...

Lots of pictures
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post #7 of 23 (permalink) Old 08-14-2010, 11:14 PM
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Re: Turbo Woes

wow thanks for taking alot of pics! That rebuilt turbo looks good. I would like to go through the turbo on both of our trucks because my dads work truck with over 300000mi prolly has some of this happening

-1997 Ford F350 cc lb srw-yanker
-1995 Ford F350 reg cab lb drw-dumper
Mine-1973 F250 fun truck

"load it like a boxcar, drive it like a nascar"

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post #8 of 23 (permalink) Old 08-15-2010, 03:27 AM
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Re: Turbocharger rebuilding and pedistal info

Thanks for the time you invested to take the nice photos and to write it all up. I think this is one to save in the library so hopefully others will chime in as well with tips.

Tom
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post #9 of 23 (permalink) Old 08-15-2010, 03:48 PM
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Re: Turbocharger rebuilding and pedistal info

If you did not replace your bearing houseing.

Remove your turbo.
Hit yourself, and order one.

I just went though this.


Turbo rebuilding is something that there is really no good info on, and we DIY'ers will suffer with constant failures from this.

There is kinda a reason out there nobody knows WTF they are doing on turbo rebuilds. It's because there isn't much info on it at all.

Tollerances seem like they woudlnt' be such a big deal with the journal bearings, but when you have a seal fail like this, it really means that something inside the bearing housing is f-ed up.
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post #10 of 23 (permalink) Old 08-15-2010, 03:52 PM
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Re: Turbocharger rebuilding and pedistal info

Here is my exhaust side bearing after a turbo rebuild and 3k miles.

New center shaft, new bearing kit, new compressor wheel.

That bearing housing is SOOOOOOOO important

As well as it is very important that the parts seal properly.

As for tightening information on the compressor wheel as well.

Little over snug.
This part will strip out SOOOo easy, I found out.
The hard way.
on my perfect wheel. =*(
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File Type: jpg bearing_1020.JPG (552.7 KB, 120 views)
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