Big Problem need help with turbo inlet fitting

[Yo Hoot]

2004 5.9 3rd Gen

Hi Tech Turbo... which is a modified Borg Warner S300

My turbo went so I sent it to Industrial Injection. They rebuilt it. Required a whole new center section and exhaust housing along with all the internals. Only part salvageable was the compressor housing. Heat damage. Had 100k hard miles on it.

I noticed when I was installing the oil inlet fitting they gave me into the oil feed hole that the threads seemed awful loose. I assumed that after the fitting seated I would be able to tighten it. After installing ithe turbo and installing the oil feed line... it was pretty obvious that the thing would not tighten and was stripping. It actually wobbles with side pressure when all the way down. Needless to say, I am livid.

As a disclaimer, I'm 61 years old, been mechanicing and am a full time machinist. I know torque and thread fits. There is something horribly wrong here.

Now I gotta figure out what's actually wrong. Was the turbo tapped wrong? Are there different size inlet threads? They supplied the brand new fitting.

If the fitting is wrong that's an easy fix. If not, it looks like I may have to drill and tap two holes in the flanges of the inlet surface. The ears are there but no holes. Then I can install one of those flange style fittings with two bolts.

One question... with the fitting not able to be tightened, will it leak? Is there much pressure there?

BTW Industrial Injection communication is horrible. They shipped late, never called me or emailed any communication. Any communication had to be initiated by me. I had to call for a tracking number. When I received the turbo there was no paper work. No invoice. Had to call for that.

Thanks in advance

 

[Yo Hoot]

Now I'm wondering if the turbo is tapped for 1/4" pipe.
The fitting they supplied is straight thread with the o-ring

 

[JohncJordanIII]

You got me beat on years of experience but being a field mechanic for all major OEM diesels your dealing with a problem that's so simple it's dumb hahaha. If it's install I would take it out. Grab any connection you have laying around and check threads and verify what THEY did. You assumed you had a awesome shop do a job and installed should of been easier then removal.

My guess is three scenarios. They made a mistake and didn't catch it during Quality control. Or they machined it to after market fittings that custom world has moved on too maybe for higher volume of oil? My third is the core is just wrong from the beginning for your application which kinda piggy back the first scenario. Either way with your experience you will figure it out but i would find out what they did so you know what your dealing with.

 

[JohncJordanIII]

2004 5.9 3rd Gen

Hi Tech Turbo... which is a modified Borg Warner S300

My turbo went so I sent it to Industrial Injection. They rebuilt it. Required a whole new center section and exhaust housing along with all the internals. Only part salvageable was the compressor housing. Heat damage. Had 100k hard miles on it.

I noticed when I was installing the oil inlet fitting they gave me into the oil feed hole that the threads seemed awful loose. I assumed that after the fitting seated I would be able to tighten it. After installing ithe turbo and installing the oil feed line... it was pretty obvious that the thing would not tighten and was stripping. It actually wobbles with side pressure when all the way down. Needless to say, I am livid.

As a disclaimer, I'm 61 years old, been mechanicing and am a full time machinist. I know torque and thread fits. There is something horribly wrong here.

Now I gotta figure out what's actually wrong. Was the turbo tapped wrong? Are there different size inlet threads? They supplied the brand new fitting.

If the fitting is wrong that's an easy fix. If not, it looks like I may have to drill and tap two holes in the flanges of the inlet surface. The ears are there but no holes. Then I can install one of those flange style fittings with two bolts.

One question... with the fitting not able to be tightened, will it leak? Is there much pressure there?

BTW Industrial Injection communication is horrible. They shipped late, never called me or emailed any communication. Any communication had to be initiated by me. I had to call for a tracking number. When I received the turbo there was no paper work. No invoice. Had to call for that.

Thanks in advance

Yes the fitting will leak if it's not tight as the supply line has pressure build up off the oil system

 

[Yo Hoot]

Yes the fitting will leak if it's not tight as the supply line has pressure build up off the oil system

Thank you.

I found the correct fitting local at a Parker Hyd store. 1/4" NPT male to 3/8" ORFS (O ring Face Seal) male

Fit perfectly

 

[RVTRKN]

I take it they tapped it for 1/4" NPT? My first thought was they tapped it to 1/4" BPT. I ran into that with an EGT sensor fitting, that would bury into a 1/8" NPT. Lucky for me I did a test tap into aluminum, before I tapped my exhaust. The vendor swore it was 1'/8" NPT, and sent me a second EGT sensor. As I researched it, I determined it was 1/8" British Pipe Thread. I ordered a 1/8" BPT tap and it fit perfect. 45 years of various mechanical related jobs, I never heard of the BPT, but I know it now.

 

[Yo Hoot]

So what happened with this is I sent Industrial Injection my turbo. I think I left the original fitting on it.
The only thing salvageable on my turbo was the compressor housing.
They rebuilt it with a new cartridge and exhaust housing plus the wheels.
Apparently the cartridge they used is tapped 1/4 NPT. The cartridge they scrapped was straight thread o-ring.
The guy that rebuilt it made a mistake and sent me the wrong fitting.
No biggy. Local supplier had it for $3.50
Scared me though as I was wondering if the threads in the turbo were bad.
Wasn't looking forward to tapping side holes in the ears for a flanged fitting.

 

[JohncJordanIII]

Glad it got figured out. Reading this got me flashbacks of accidentally buying undersized bearings once for a 12v71 Detroit lol

 

[jhenderson]

I take it they tapped it for 1/4" NPT? My first thought was they tapped it to 1/4" BPT. I ran into that with an EGT sensor fitting, that would bury into a 1/8" NPT. Lucky for me I did a test tap into aluminum, before I tapped my exhaust. The vendor swore it was 1'/8" NPT, and sent me a second EGT sensor. As I researched it, I determined it was 1/8" British Pipe Thread. I ordered a 1/8" BPT tap and it fit perfect. 45 years of various mechanical related jobs, I never heard of the BPT, but I know it now.

British pipe thread used to be quite common on European hydraulics. Think JCB equipment.

 

[Ozymandias]

British pipe thread used to be quite common on European hydraulics. Think JCB equipment.

It's still the standard for all water and propane fittings all around Europe.
Only compressed air fittings are traditionally NPT in Europe.