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Discussion Starter #1
Pulled cab to bulletproof my 05 with 80k miles. Turbo was removed and put on the floor till it was ready to be put back on. This turbo was a warranty Ford turbo replaced at 50k so only 30k miles most towing and had no issues. I did pull the end cap off the piston and use a magnet to actuate the vanes and was butter smooth. Started the truck up and it sounded deep and not like a shop vac. Only put 10 miles on it and it did make boost but was watching other things. But it never sounded like a jet like this truck always did at idle.


Truck wore a rod bearing down and cab off and motor rebuilt. Turbo rebuilt, cleaned and KC wheel added. Truck sounded the same low tone and no shop vac sound. VGT wiring was looking bad so that connector was also replaced. Truck ran nice again for 10 miles till I found babbatt in the oil again.


Cab off motor out again and found a cam bearing babbett layer pealed off but still babbett under it. Something I never saw before and its back together. No codes, will boost 20psi max on street tune with atlas 40, colt stage 2 cam, MBRP exhaust no kitty. Turbo is laggy and makes no boost for a while, EGTs are higher everywhere but truck runs pretty good. Fuel pressure is 60psi and new filters installed, new VGT solenoid installed with no change, slight change in tone when VGT is unplugged so it is doing something, battery voltage measured at connector with key on. The vgt piston is 1.9 inch from casting to piston down with VGT solenoid removed and .775 inch from casting piston out as far as it will come. Again VGT system is butter smooth and I spent hrs moving it back and forth with a tinny magnet. Tried VGT re-learn no change. Any ideas???
 

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did you do a VGT relearn? if not that might fix it, either way that should be done after the type of work you did.
 

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"resident smarty pants"
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What are your EBP, MAP, and Baro readings at KOEO?

Have you checked to see if the EBP sensor is plugged? How about checking the EBP tube for carbon plugging? MAP sensor hose in good shape (no leaks or plugging there either)?

Did you identify the babbitt material in the oil by UOA?
 

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Discussion Starter #4
map hose is good along with intake nipple. Pulled engine apart to find one cam bearing looks like a layer of Babbitt fell off, all Mahle cam bearings were on the tight side and not the roundest. The bad spot gave me .002 oil clearances so I cleaned it up and put it back together, cam spun nice in the block. I wasent going to pull the heads for a 3rd time to pop out one cam bearing.
 

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Discussion Starter #5
First time I took the truck on the highway and put some mileage on it. Looking at the VGT on forscan the compute seems to command really low VGT %. I posted a WOT run and you can see vgt 15% but why??? Its possible the truck was not warm enough to do a VGT re-learn, usally around 175' by the time the batteries get hooked back up.
 

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IMO talk to your tuner. If it’s a desired issue by the pcm is the programming. The first thing I Noticed that the desired EBP is very low on all your snap shots. Low desired EBP results with low VGT
 

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Discussion Starter #7
I have been running the same tunes for 10 years, never did anything like this. Only change was the Atlas 40 and my understanding is that's strictly fuel.
 

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Discussion Starter #9
Tried stock and my tow tune several times and they are both significantly worse. Jake brake in tow tune does not work they way it used to, should lock up the rear axle without a trailer. Im pulling the EBP sensor today and inspecting. It seems to be reading properly but it seems to effect the VGT the most threw the ECU.
 

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Discussion Starter #11
Tube is clean and sensor was clean. If I unplug the EBP sensor tone changes about the same as when you unplug the VGT solenoid. So again system is working but it commands very low VGT %. Highest I have seen is around 60% at a warm idle driving is usally 40-50% and WOT 15% all way too low. Im stumped.
 

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Do you have a scanner that can change the VGT cycle on demand to see if it’s capable of a full sweep? The only other thing that I can think of you may need to get your tunes adjusted for the camshaft. Other than that I have to ponder this some more.
 

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Discussion Starter #13
It did this before the cam been 3 months of bad luck to say the least. I don't know if forscan can demand VGT % if I pay for the extended license. Something to look into. I did push the VGT piston in all the way and did hear the vacuum cleaner sound for a second till oil pressure pushed it back. My guess is its capable but computer will not allow it.
 

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Well that rules the cam out. For ####s and grins do you have another spare pcm to try?

Have you triple checked for pre turbo exhaust leaks?
 

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Jackleg Mechanic
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IMHO if you had the turbo out and it's not spooling right now you should start by disconnecting the up pipe and make sure that that connection is correct. It's a big issue when reconnecting the turbo.
 
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