4th Tubocharger on its way out

[JCarlisle]

I have a 05 6speed with Pac Brake and it is going through a turbo about every 5 to 7000 miles now they start to leak into the intercooler.

The first failure (25K)was the worst 2 runaways but able to control as truck was in gear and on road both times. The truck was burning a quart of oil every 250 miles be fore it started leaking out of the center section of Turbo.

Dodge Dealer is very helpful and so is Pac Brake I have installed a back pressure guage on the Pac Brake and the highest back pressure that I have seen is 60 psi.

I have been doing Oil Samples on the Truck since it had 10K miles on it At 20K

I started to get high readings on copper just before the first turbo failed.

Dodge is starting to Blame the Pac Brake and is getting tired of changing Turbos Has any one else with this combination had this problem.

Does anyone else with a 2005 have a current oil sample.

The Truck has 56K miles on it now.

The turck has never had a tuner or any other device on it and it will make 32 lbs of boost under load.

 

[HBarlow]

Turbo failures on unmolested Cummins engines are not common. I put lots of miles on an '01 and an '06 and have never had a turbo problem. Have known lots of RV transporters and a couple of oilfield hotshotters who put hundreds of thousands of miles on Dodge Rams and have never replaced a turbo.

 

[SSalzer]

My turbo is currently leaking oil out of the bottom of the larger housing. I also have a Pacbrake. I took off the boost hose and oil appears to be migrating into the intercooler. Could PRXB be the problem???? What did Pacbrake have to say about it?

 

[ENafziger]

On DTR, a member named Roperteacher has been going through the same problem. I believe he's on his 3rd turbo, and the dealer is blaming his PacBrake...

--Eric

 

[BEmmert]

Interesting... . I have gone through several seal kits and now a new cartridge on my turbo and what do ya know, I have a PacBrake. I was kind of suspicious of the brake being the cause and now I am really starting to wonder. Mine is a 98. 5 and I have the older version of the brake, but it can reach 60psi under load.

 

[JCarlisle]

Pac Brake Says that the back pressure is within Cummins Spec and ATS says that the Pac Brake is the only brake they install and they have seen no problems

 

[burnin oil]

Pacbrake on my 04. 5 has been there for the last 50k miles and the truck has 81k on the clock. Still on the original turbo. I have pulled 15k pounds with the trailer for several thousand miles now and run a smarty programer on 90 HP for the last 25k miles. Interesting problem that yall are having.

 

[AH64ID]

For reference the OE Jacobs Exhaust Brake will hit 63psi.

 

[RVTRKN]

For reference the OE Jacobs Exhaust Brake will hit 63psi.

The main difference is, Jacobs will not effect the warranty. Remove the EB for twice the miles your having to replace them and see what happens, then reconnect it, if you dare. If I add a EB to my 04. 5, it will be a Jacobs EB that Dodge/Cummins will stand behind if the turbo starts to have problems.

 

[JCarlisle]

Has any one got any oil test data on these Trucks Mine has been showing a high copper content since about 5kmiles before losing the first Turbo

 

[BDaugherty]

Has anyone done any failure analysis on their failed turbos?

 

[JCarlisle]

Dodge has all of my failed Turbos but the one on the truck now that is starting to leak I would love to have it analized if I knew where to send it

 

[HBarlow]

Hmmmm. Both my previous Dodge Rams, an '01 HO/six speed and an '06 w/48RE had Jacobs Exhaust Brakes from Day One which I used 100% of the time.

 

[sag2]

A couple of things. First, the turbo needs to be pre-oiled before installing. I doubt this is the cause but it should be ruled out. Second is a good supply of clean oil. Was the oil and filter changed with each turbo? Was the feed line changed/checked or tested for flow? Third, these turbos don't generally fail and Chrysler is going to get tired of paying for turbos that are being replaced that are most likely not their fault. Lucky for you your dealer does not sound too bright or he would have shut you down on number three with the identical failure.

RVTRKN has the best idea, pull the brake for 10,000 miles and see if you have a failure.

 

[DCreed]

I have seen many a compressor oil seal leak from crankcase pressure after install of twins. Perhaps the the pac is causing an increase in crankcase pressure thereby causing the seals to blow out on these turbos. is the pac brake vacuum operated or use an air compressor? failed/leaky vacuum pumps often cause excessive blow-by on these engines, coupled with the added pressure from the brake may be too much for the breather to handle.
As previously stated, knowing why these turbos failed is the key to preventing future failure.

 

[ENafziger]

Has any one got any oil test data on these Trucks Mine has been showing a high copper content since about 5kmiles before losing the first Turbo<!-- google_ad_section_end --> <!-- / message -->

I have routinely had high copper readings from the last couple samples I sent to Blackstone.

I had the Jacobs exhaust brake installed by the dealer when the truck was new. Changed to a SPS 66 turbo at about 20k? Vacuum pump went out on the brake at 35k. Now the brake isn't working again at 63k, but the vacuum pump is alright. Turbo is doing great as well.

--Eric

 

[TCDiesel]

Has the Dealer check the Crankcase Tube?

 

[Bob4x4]

Has the Dealer check the Crankcase Tube?

Turbo drain ?

 

[JCarlisle]

The Dealer has done a Oil Pressure Test and they said that they checked the Drain. They say that there are no Problems with Oil flow.

The Pac Brake uses a air cylinder and a remote mounted electric air compressor for Brake operation and it doubles as an onboard air source for airing up tires or other things a small reservoir of compressed air would be good for. It has come in handy several times.

As for Crank Case Back Pressure that is a new theory that is worth exploring.

 

[TCDiesel]

Yep that's a Tip, Some owners will use the Brake for long Periods of Low RPM Warms up, it is than possible to cause excessive crankcase back pressure this may cause crank case pressure to exceed the Oil Pressure, if the tube is clear you should be OK. . Highly unlikely but it's possible.