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Continously blowing same gasket!

Discussion in 'International Forum' started by philjo, Apr 27, 2013.

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  1. Apr 27, 2013 #1
    philjo

    philjo Light Load Member

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    Dec 22, 2008
    Indiana
    0
    I really hope someone can help me out here with my Isx, which btw is a 04 . A few weeks ago maybe longer, truck started blowing black smoke and noticable power and mpg loss. I first changed all filters with no luck. Then I noticed an odd sound coming from under the hood on right side that resembled the sound of a 100 birds chirping. Took it to shop and found gasket between exhaust manifold and turbo blown so we replaced. 2 days later same thing! This time they said the manifold was concaved so we replaced center section of manifold with a new one and again new gasket. Maybe a week later, same..only this time the turbo flange was cracked! So I bought a reman and installed with new gasket. Next day the #### thing blows again! So this time we replaced my muffler for a Donaldson which seems to flow much better btw. Well guess what...its blown yet again and myself nor the shop knows why. I will tell you my egr valve is disconnected and has been for approximately 100k because truck runs 10 times worse plugged in. During hard pulls it still blows the heavy black smoke with new gasket. The only two things that was done anywhere near the time I started having this problem was an overhead ran 1 week prior and replaced the exhaust pressure sensor about 2 weeks prior. Im thinking of replacing the egr with a new one this week and plugging it in as should be but really don't want to waste anymore money if its not going to help. Any advice is greatly appreciated as always!
     
    philjo, Apr 27, 2013
    philjo, Apr 27, 2013
    #1
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  3. Apr 27, 2013 #2
    MNdriver

    MNdriver Road Train Member

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    have you had the head checked for warpage or true.

    And that would be with a machinist straight edge too. You'd have to pull the manifold to check.
     
    MNdriver, Apr 27, 2013
    MNdriver, Apr 27, 2013
    #2
  4. Apr 27, 2013 #3
    Heavyd

    Heavyd Road Train Member

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    So the turbo flange gasket to exhaust manifold is the one that keeps leaking?
     
    Heavyd, Apr 27, 2013
    Heavyd, Apr 27, 2013
    #3
  5. Apr 28, 2013 #4
    snowwy

    snowwy Road Train Member

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    my guess would be the turbo. not spiining so it's like a plugged exhaust.

    i've had an 05 and 07 isx. everytime i blow black it's becuase the turbo isn't spiinning at 45,000 rpms

    the chirping noise i've experienced is becuase the plate inside the 2 turbo sections is spinning around the housing. biggest problem with those turbos.

    was your tested for rpms?
     
    snowwy, Apr 28, 2013
    snowwy, Apr 28, 2013
    #4
  7. Apr 28, 2013 #5
    double yellow

    double yellow Road Train Member

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    I have no serious experience with turbo diesels, but considerable experience with gas & alcohol burning turbo cars so take this with a large grain of salt:

    I suspect excessive egt's are causing exhaust components to warp & gaskets to blow. And EGR, at least in conventional engines, lowers egt's (which is why it is there, reduced combustion temps lower NOx emissions) so I suspect the two are related.
     
    double yellow, Apr 28, 2013
    double yellow, Apr 28, 2013
    #5
    Heavyd Thanks this.
  8. Apr 28, 2013 #6
    philjo

    philjo Light Load Member

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    Dec 22, 2008
    Indiana
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    Heavyd, Yes..its the gasket between the turbo and exhaust manifold and Ive replaced the turbo with a reman so I dont suspect its the turbo because it continues to blow.

    Mndriver, the gaskets between head and manifold hold up fine but the answer is no I haven't had it checked.

    Doubleyellow, thats kinda what i was thinking but the engine runs much cooler with egr disconnected.
     
    Last edited: Apr 28, 2013
    philjo, Apr 28, 2013
    philjo, Apr 28, 2013
    #6
  9. Apr 28, 2013 #7
    snowwy

    snowwy Road Train Member

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    my first replacement turbo lasted 2 weeks before the plate broke again. the second lasted 6 weeks. the 3rd lasted long enough for me to leave the company.

    but this was on a 09 389.

    original brand new doesn't last long. remans are even worse.
     
    snowwy, Apr 28, 2013
    snowwy, Apr 28, 2013
    #7
  10. Apr 28, 2013 #8
    Heavyd

    Heavyd Road Train Member

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    Yes, it does sound like maybe there is too high exhaust temps, or the turbo is overheating all the time. That turbo should have coolant lines going to it. I wonder if there is a coolant flow problem through the turbo causing it to overheat and blow the gasket.
     
    Heavyd, Apr 28, 2013
    Heavyd, Apr 28, 2013
    #8
  11. Apr 28, 2013 #9
    truckmechanic

    truckmechanic Medium Load Member

    534
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    Jan 14, 2012
    Hi Desert Ca
    0
    Make sure the bolts are torqued to 80ft and that all the studs are new and not stretched or damaged not allowing you to get proper torque the factory spec of 65 is not enough i find the nuts back off all the i time,i don't think you have a back pressure problem i have seen to many come in to the shop with completely plugged after treatment filters to where they wont run and been getting that way for months with no blown turbo flange gasket 99% of the time its the studs or insufficient torque to start with,i also would say its not a egt problem as same basic turbo/ gasket on the 07 up product with the after treatment and doser and there running a lot higher egt unless when the over head was set the injectors were incorrectly set bit i would suspect other problems if that were the case
     
    truckmechanic, Apr 28, 2013
    truckmechanic, Apr 28, 2013
    #9
    Cranky Yankee Thanks this.
  12. Apr 28, 2013 #10
    philjo

    philjo Light Load Member

    138
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    Dec 22, 2008
    Indiana
    0
    Plugged treatment filter....Meaning the coolant filter??? This is something I haven't thought of.
     
    philjo, Apr 28, 2013
    philjo, Apr 28, 2013
    #10
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