Turbo rebuild

[syoungs]

So if you were to buy new , what would you get for a 7.3?  Any experience with d66

is the rest of the truck stock? a stock turbo on a stock or tuned truck is a good match, throw in some 160cc injectors, bigger oil, and aggressive tuning, a d66 becomes a really good turbo for the e99 and older rigs.

[Happy Gilmore]

How often does a turbo need a rebuild? In my past job we cooked through 3-4 sometimes 5 trucks a year. Never really had many turbo issues. We dumped all the trucks at 200-225k miles. They pulled 14k trailers every mile all over the west coast and rocky mountain region. Seemed like the turbo was never a issue on any except an occasional boot failure
 

[KFhunter]

mine went out because it's running higher than recommended boost and a triple disk converter with a stiff engagement - causing turbo bark if you miss the shift point and back off the throttle too late.

[syoungs]

Pretty reliable under stock conditions, you start increasing the drive pressure and they eat themselves pretty easy

[KFhunter]

yup - I've been detuning it. 


Stock I was sick of the truck as it's a 1995 auto which was sickly for power.  You couldn't pass anyone because it would shift down, RPM goes up and it would cut back the fuel so you sat there doing nothing.  Couldn't tow due to the same thing, down shift causing defuel. 


So I went a little over the top getting it to drive decent, now it's just about right for power but I can't get the trans to behave. 


It's getting traded for a 6 speed dually 4 door eventually.

[Happy Gilmore]

yup - I've been detuning it. 


Stock I was sick of the truck as it's a 1995 auto which was sickly for power.  You couldn't pass anyone because it would shift down, RPM goes up and it would cut back the fuel so you sat there doing nothing.  Couldn't tow due to the same thing, down shift causing defuel. 


So I went a little over the top getting it to drive decent, now it's just about right for power but I can't get the trans to behave. 


It's getting traded for a 6 speed dually 4 door eventually.

That's what always has irritated me with my 2002 7.3. Just when its pulling it will downshift and spin. What's the easiest way to reliably improve it on a high mile truck without eating it up?

[Zardoz]

WOW, can you guys speak English or refer me to a web site for education?  Friend of mine just bought a 2010 Ford with a turbo and I would like to learn more. 

Thanks............

[n_mathews13]

So if you were to buy new , what would you get for a 7.3?  Any experience with d66

is the rest of the truck stock? a stock turbo on a stock or tuned truck is a good match, throw in some 160cc injectors, bigger oil, and aggressive tuning, a d66 becomes a really good turbo for the e99 and older rigs.

Most is stock. I have been working my way up. I do have a tunes and a few little things. I have a boost leak that I am tracking down . So that's why I am just rebuilding for now ( that way I don't spend a ton of money on something possibly isn't the problem. In past a up graded turbo and injectors will be put in. For now just fix a boost leak. I will pull motor for it since I have to drop oil pain cause of a oil leak. Project has gotn bigger before I have even started lol

[HuntnFishnRyan]

make sure to check the casting for cracks before spending any money on it. One common place is by the waste gate. There is a few techniques for checking it. If its cracked just throw it in the scrap bin. 

[dyhardhuntr]

WOW, can you guys speak English or refer me to a web site for education?  Friend of mine just bought a 2010 Ford with a turbo and I would like to learn more. 

Thanks............

You can search YouTube and find a lot of good info. Turbos aren't rocket science. Once you learn how they work it's a piece of cake. Older turbos have a fixed wheel on both ends(intake and exhaust side). Turbos are driven from the exhaust gas exiting the engine. That in turn spins the intake side which sucks in air from the filter housing and pushes it out the elbow that goes to the intercooler(which is basically a radiator minus the coolant). The air is cooled through this and goes into the intake on the engine. Newer diesels have variable geometry turbos which have a housing or cone that will slide closer or farther away from the intake compressor wheel based upon engine load, fuel position and such. These turbos help eliminate turbo lag by allowing boost to be present right away. That's why a lot of guys put bigger compressor wheels on. More boost. The only thing is that you have to watch your boost gauge. To much boost allows for a lot of cylinder pressure that can cause blown headgaskets. If I was the op I would buy a stock factory reman turbo. Don't go cheap. You'll pay for it later. Also prelube that new turbo before you start the truck. Lube the internal bearing. Also the #1 killer of turbos is heat. After you are done driving it DONT shut it off right away! Let the truck idle for 5 min or so to let it cool down.

[Mudman]

Google Austin Tater turbos.  He rebuilds and builds custom turbos.  Out of Ohio.  He is real good.  He machines housings etc.  My 05 Dodge is doing great.  Stock Holset which he machined out increasing size a lot yet maintaining stock like feel with no lag.  Its a whole new truck.  Much cooler and stronger.  Turbo makes more boost so I have to set tuner to keep from blowing head gasket.  1200$ is about what I paid for this.  Keep in mind on your Ford that up pipes should be replaced from old leaky donut gasket to the International pipe set up.  EBPV eliminated and a wastegate may be required if you put aftermarket turbo on or you can blow heads easily with too much boost.  Also your injectors are only going to push so much fuel so don't go too big unless you replace them larger.  Are you after power or cooling?  Most guys put turbo on which is too big only to be disappointed.  Air filter and exhaust help these trucks cool better too.  Also the auto trans will go if you make more HP.  Guaranteed.

[Happy Gilmore]

Google Austin Tater turbos.  He rebuilds and builds custom turbos.  Out of Ohio.  He is real good.  He machines housings etc.  My 05 Dodge is doing great.  Stock Holset which he machined out increasing size a lot yet maintaining stock like feel with no lag.  Its a whole new truck.  Much cooler and stronger.  Turbo makes more boost so I have to set tuner to keep from blowing head gasket.  1200$ is about what I paid for this.  Keep in mind on your Ford that up pipes should be replaced from old leaky donut gasket to the International pipe set up.  EBPV eliminated and a wastegate may be required if you put aftermarket turbo on or you can blow heads easily with too much boost.  Also your injectors are only going to push so much fuel so don't go too big unless you replace them larger.  Are you after power or cooling?  Most guys put turbo on which is too big only to be disappointed.  Air filter and exhaust help these trucks cool better too.  Also the auto trans will go if you make more HP.  Guaranteed.

So, $6-8,000 more on a truck like mine which is realistically worth $8,000?

[Mudman]

No, actually the opposite.  I was trying to point out the mistakes of people and their oversized turbos and that it isn't really a great idea to eliminate wastegates.  I gave knowledge so own opinions and decisions can be made.  I sent my stock turbo in to Austin and he machined it and rebuilt it with quality (not Chinese) billet wheels and parts while retaining full stock compatibility.  It is now a 62/65/12.  Much better than stock and at 1200$ much cheaper than buying a new quality turbo.  Ebpv isn't $ to eliminate and up pipes all leak stealing boost thus people think turbo is worn out when its not!  Up pipes leaking is just one of those things all 7.3 guys have to deal with.  Or you can just boost 20psi all day and run it.  I loved my 01 Ford but Cummins is so much cheaper and better-sorry.  Another HUGE tip is put aftermarket fuel filter on before it cost you 5000$!  Stock filter is totally worthless.

[Happy Gilmore]

Just did up pipes at 240,000k. Good improvement, had a lot of leaks. Our 2003 Duramax dog truck is chipped and piped. Only 100k. I just don't feel confident it will have the lifespan of a stock truck. It's fast which, trucks shouldn't be. Just the tuner and exhaust was about $2,500. Folks add fuel filter, beefed up granny a couple thousand, couple hundred, turbo work, a thousand, injectors couple thousand, high cap fuel pump thousand, coolers another thousand then, gotta have a lift, tires and wheels. That's all I meant by a $8,000 truck with $8,000 in add ons.

And a new stock rig has 500 hp and 1,000lbs torque.

[Mudman]

True.  60k$ for new one or build your own.  Choices.  I have tuner 1k, turbo 1200 and fuel filter mod 57$. Exhaust300$.  400+hp and 800+tq or more if I want to abuse it.  But towing is strong and cool at 400+hp.  But mpg is great and I doubt many new diesels can match.  Guys I talked too gripe with all the emission crap 12mpg is average.  If true that's 60k not well spent.  Older diesels are worth it in my book.  Resell worth aside, compare it to what you get new at 60k$$$$.  I don't know why more power is really needed.  350hp and 700tq will do most anything.