OMG!! D-Max Turbo rebuild.

[NIsaacs]

I am sure a D-Max has it's place, but not in my little shop Give me a Cummins to work on any day.

My son has a small tire store/repair shop and asked me to rebuild a turbo off of an '08 D-Max. The customer had it to a dealer who replaced the complete exhaust system because it was plugged up and advised him there would be no warranty to the repair because the engine was wore out. A week later it plugged up again so he brought to Jeff. The cab is off and the bed is full of pieces and parts, I almost left!!!:-laf

I think he should have replaced it with a recon but thats not my call. It had two bad injectors and oil running out of both ends of the turbo, especially the exhaust side. All I did was rebuild the center section. My experiance with small turbos on Allis Chalmers tractors of the 60's was rusty to say the least, they were small and simple, not 50# monsters with VGT.

The Turbo (Garrett) had been very hot, the Dynamic seal (like a piston ring) was collapsed on the turbin side, the thrust bearing was wore out and the shaft bushings were loose. I am not sure I like the design of the shaft, it is about a half an inch in diameter but it necks down to about 5/16" and threaded at the compressor wheel. I am so glad I don't have to replace the cab, it reminds me of "pick-up-sticks"

Nick

 

[NIsaacs]

Talked to my son tonight and he said the D-Max is running great, turbo singing like it should. I guess I got the VGT actuator in time, it had me a little intimidated



Nick

 

[JR]

Do you know why the exhaust plugged up twice in one week? Im kind of guessing that engine had a few miles on her? At least Im hoping so for the owner, 2 bad injectors and a fried turbo on a 4 yr old rig would scare me!

 

[NIsaacs]

Do you know why the exhaust plugged up twice in one week?





I am assuming from the oil dumping out of the turbo, but I don't know much about EGR, DPF and deletes so I don't know how all that works. The dealer thought the engine was wore out and dumping oil in the exhaust rather than the turbo. The exhaust manifolds looked great so I don't think any oil was coming from the rings. The exhaust turbin housing had been very hot, (discolored) with the seal collapsed and soft, I guess heat from the plugged up exhaust system. I really didn't like the design of the turbo. The compressor side seal only seals about 2 or 3 thousands on the thrust bearing hub so when it gets about 4 thousands wear it can leak, which it did. I called the company that sold the repair kit about it and they said that was the only D-Max turbo like that and wasn't impressed either.



My son said he did the delete which requires a programer, so he set it on the lowest setting but that it still felt like a hot rod.



Nick