HP turbo blew, need removal tips and advice

Discussion in 'International Forum' started by kubasj05, May 22, 2019.

  1. kubasj05

    kubasj05 Light Load Member

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    So today is a day, my high pressure turbo blew seals and God knows what else.
    Oil in pipes and air to air intercooler (don't know what am I going to find after disassembly.
    My observation and work I've done so far, removed most piping except one that feeds Hp turbo from water to air intercooler (gotta drain coolant for that first) for compressor wheel inspection if that is even in one piece(I hope it is)
    Now, my questions:
    1. Is there any way to clean air to air cooler without removing it (saturated with oil)
    2. If water to air cooler is saturated with oil, do I have to remove it for cleaning?
    3. Hp turbo is mounted to exhaust manifold 3 nuts or 2 nuts and one bolt (I don't know the combination just yet) 2 nuts on top are accessible, the 1 on the bottom is not accessible due to low pressure turbo compressor housing. Do I have to loose lp turbo housing and move it 1in or so to gain access to that Hp turbo lower manifold bolt/nut? I don't see it happening any other way.

    Any tips and suggestions are welcome, if you did this job before what is the quick walk through the process of removing and installing, what other preventive things would you do while being there.
    Thanks in advance, Jacob
     
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  3. Heavyd

    Heavyd Road Train Member

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    The high pressure turbo (maxxforce 13) can be replaced as just the center cartridge. You don't need to pull the whole thing down. The main air to air does need to be removed for proper cleaning, but the intercooler can be cleaned out by stuffing rags down it and pulling them out. I would not be afraid of the residue oil left over in the cooling fins.
     
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  4. RustyBolt

    RustyBolt Road Train Member

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    If the fins came apart (keyword if), I would probably replace the cold air charger/intercooler/air to air (whatever you want to call it). Wouldn't take a chance on sucking a piece through the motor if it were me.
     
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  5. kubasj05

    kubasj05 Light Load Member

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    So, hot side housing (turbine) can be left attached to exhaust manifold and the only thing that would be switched is a cartridge and reassembly of compressor side, that is great news then. What is the size and bolt pattern holding cartridge btw?
    Do dealers sell cartridges without housings? I called them and they said they sell whole turbo unit with core exchange? That sounds like it's a reman, is that right?
    Would you happen to know if there is o-ring kit available for piping only?
    Also, turbo oil feeding line bottom gasket and upper o-ring are available in the kit or by themselves?
    Along with all this turbo mess I will be replacing CCOS as I have it and it's right there.
     
  6. Heavyd

    Heavyd Road Train Member

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    SERVICE PARTS INFORMATION

    MaxxForce 11, 13, and 15 Engines

    Kit Description Part Number Quantity Required
    Turbocharger Oil Supply Line (11/13L) 3018397C9x as needed
    Oil Supply Line Fitting Kit (Used to install the 11/13L turbo supply line for the first time) 2512772C9x as needed
    O-Ring Seal (if needed) 1820907Cx as needed
    Kit Turbocharger High-Pressure Cartridge 13L 2511792C9x as needed (not sure what is all included in this kit)


    The turbo oil feed line is one-time use. So you need a new one.
     
    baha, QUALITYTRUCK and kubasj05 Thank this.
  7. kubasj05

    kubasj05 Light Load Member

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    2019-05-24_121040.jpg 2019-05-24_121158.jpg 2019-05-24_121056.jpg 2019-05-24_121112.jpg 2019-05-24_123433.jpg 2019-05-24_123624.jpg 2019-05-24_123821.jpg 2019-05-24_125920.jpg
    Thanks Heavyd, very helpful indeed. Here's the aftermath
    Broken shaft, piece of compressor wheel fused in the housing, turbine wheel milled down, whole lot of damage.
    Question to Heavyd:
    Is there any sealant required to be used on mating surfaces between hot side housing and the cup that seals exhaust gases. I had really hard time to remove that piece form housing, it had lots of rust buildup after getting it out I thought there must of been some sealant involved, I may be wrong but wanted to hear from a professional. Any tips on cartridge installation?
    And how crucial is new turbo feed line as it looks like another knuckle scrapper, lol
    I cleaned up piece of tubing where o-ring is located with 500 grit sandpaper, everything looks great.

    Now I got turbo seal kit, it looks like it contain more o-rings (I understand it service both turbos) but still there are some pieces that are there but were not upon disassembly. For example, turbo return line had orange o-ring only where turbo seal kit has those flat paper gaskets in addition to o-rings. Do these need to be installed along with o-ring? If so, which side goes up as one side has sealant around the bore.
    Based on stuff I've taken off, these are the only seals that I need replace,is this correct?
    I don't know where goes 1 purple o-ring, 2 black o-rings and 2 metal rings with rubber fused into them. Would you be able to shed some light on this, thank you
    Jacob



    2019-05-24_121040.jpg 2019-05-24_121158.jpg 2019-05-24_121056.jpg 2019-05-24_121112.jpg
     
    Last edited: May 24, 2019
    Heavyd Thanks this.
  8. Heavyd

    Heavyd Road Train Member

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    The center section has no seals where it slides into the exhaust sections there. They just rely on heat and the v-band clamp to seal it. Just make sure it is nice and clean so you don't have to force it in to cause any potential damage. Clean all the rust out. They do not recommend reusing the oil feed line due to the flex section being handled during removal. The flex section gets hard and will crack if bent around too much and possibly cause a leak or even burst. So it is up to you if you feel it is ok to reuse. In the manual, they recommend to install the center section loosely, then install your new seals on the turbo inlet flange and the inlet pipe. Then install that inlet to the outlet of the intercooler. Then pull out the center cartridge slightly to engage the inlet pipe and slide the center section back home to complete that assembly. Sometimes this works and other times you still have to wrestle everything to line up, like you did when it came apart.
    Turbo drain line, just install the paper gasket, I put the orange side to the tube.
    The others seals are left overs if you did take the lower turbo off. If you also replaced the oil feed line, it intersects the oil pressure sensor and the other seals are for that.

    Just for fun, warranty pays 2.3 hours for this job! LOL!
     
  9. kubasj05

    kubasj05 Light Load Member

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    Get out! 2.3 hours? I've spent 2.3 days on this thing. I'm ready to be lay to rest, my back feels like I'm 99 years old and legs like they are made of chop sticks.
    I already installed an o-ring on turbo drain (I can change to paper gasket if you think it is better) and decided to give it a shot at going with old oil feed line for turbo.
    Cartridge installation is something else, wow, that was a test of my will.
    I've cleaned all the rust on hot side housing and used file to remove unevenness caused by rust of course. During cartridge installation I've made sure that turbine wheel is spinning freely because it wasn't at first when I was tightening up the v band clamp.
    Here she is in her new home and the leftover from brand new BW TURBO.
    Thank you Heavyd for your patronage, it would be a hell without your knowledge and help. You deserve tall beers from me, sir
    2019-05-24_193423.jpg 2019-05-24_193559.jpg
     
    Heavyd Thanks this.
  10. Heavyd

    Heavyd Road Train Member

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    Great job! You're welcome!
     
  11. kubasj05

    kubasj05 Light Load Member

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    A little update, I test drove the truck for approximately 25 miles and it runs good. The only difference to my old turbo is sound. New one is quite louder as it sounds like a high pitch hair blower at between 20-40 psi of boost. I'm not sure if it supposed to be like that, as I didn't have same sounding old turbocharger. I'm somewhat worried about it but truck pulls good and everything else seems to be good.
    I'll see how it goes Tuesday next week when I'm back at work.
    Happy Memorial day weekend everyone
     
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