Blown turbo. How much metal shavings is too much?

[Muddy Bean]

Jeff,

I have looked into aftermarket and larger turbos. My only issue is that it really does require other follow-up like a major tune overhaul, and other engine bits to make them actually useful and the turbo price goes from $500 to $2000 per side so I just can't justify it in my family hauler...but trust me, I've been tempted to turn the truck into a monster and may someday. For now, I just want it back on the road. New turbo arrives tomorrow and hoping to get it slapped in there this week.

 

[Muddy Bean]

Got the older turbo out. Tons of play in the bearing. Impeller fins damaged of course. Manifold is indeed warped and one of the studs is broken (I expected this) so I’m replacing the manifold as soon as I get the old one off and the broken stud drilled and tapped. I have worked a couple half days at this. It’s not for the faint of heart. Just really tight clearances which required me to buy a bunch of random tools to make it all work. Not a bad thing but yeah, only tackle this if you’re broke and bored of which I’m neither so not sure what I was thinking

Circled in red on the manifold shot is the stud that broke. It’s common on these. Also circled in red is the soot stains above the left side of the manifold which is a classic sign of warpage and boost loss.
Red arrows in another photo is the nicks and damage that occurred on the inside walls of the turbo outlet tube. Crazy. Bearing failure on these is pretty no bueno.

 

[Muddy Bean]

 

[jeff kushner]

Nice pics, of ugly stuff.....Those studs in cast iron, the prefered method, sure do break pretty regularly. I plan and spray for days to avoid it.... sorry you had to do it but you saved a crapload of cash!

You can get yard robots for what you saved! Meet Hose-A and of course.....Hose-B, they are twins.....

 

[Muddy Bean]

Got the broken stud out finally with a little welding. New gasket, manifold and turbo are back in a torqued down. All plumbing is returned. Going to pull pipes on intercooler and make sure it’s drained of oil/etc. Oil pan and filter contain no noticeable metal thankfully. Once coolant and oil are filled I’ll pull the ECU plug and crank the engine to prime the turbo with oil, and then fire her up today. Hopefully no leaks or any other annoying stuff. Going to check the other turbo too just to be sure she’s still healthy (was replaced 90,000 miles ago).

 

[Boostedbus]

Thanks for the post and pictures. Glad you got it back together and ready for many more miles!

 

[JExpedition07]

Enjoy the clean new exhaust manifold while it lasts…..they don’t look like that for long LOL.

 

[Muddy Bean]

so the project took on more days when I realized my jiffy tite fittings were leaking coolant. Tore turbo back out, replaced both the passenger side block fitting and line as well as the head fitting and line. Let’s just say, you never ever ever want to have to do this. It was a HUGE (and I’m not exaggerating) pain. So my passenger side turbo, gaskets, manifold, gasket, oil line gasket, coolant lines and all four jiffy fittings are brand new now. Should be good for a while.

 

[Muddy Bean]

Done!

 

[Boostedbus]

so the project took on more days when I realized my jiffy tite fittings were leaking coolant. Tore turbo back out, replaced both the passenger side block fitting and line as well as the head fitting and line. Let’s just say, you never ever ever want to have to do this. It was a HUGE (and I’m not exaggerating) pain. So my passenger side turbo, gaskets, manifold, gasket, oil line gasket, coolant lines and all four jiffy fittings are brand new now. Should be good for a while.

Thanks for the warning. I’ll probably pass on that job if it comes about with mine. I’ve done somewhere around 20 engine transplants on over the years of side wrenching and the last one about killed me. I have trouble seeing in tight spots anymore and can’t get enough light where I need it. I also have lost a tremendous amount of patients in my older age and my poor vision intensifies that. I need new header gaskets on my big block Cougar and the clearance between them and the shock towers is barely a sheet of paper thick (no exaggeration). That job usually takes all day. I gotta remove motor mounts and jack up engine just to access the bolts with a open end wrench. Then several of them you get a quarter turn and then you gotta go underneath to get the next quarter turn on that same bolt because of clearances. I do that back in forth for maybe an hour on one bolt. It’s total insanity! I guess it lives up to the definition of a muscle car though, a big engine squeezed (understatement) in a small intermediate car.