BD HX-40 dead <500 miles(long)

[shawn huizenga]

Just got a brand new BD Power HX-40 installed the night before last and have been really impressed with everything about it, spoolup, noise, etc. I babied it all the way home(210 miles), then drove around home some, playing with it a little but nothing excessive IMO. Put a new VP-44 in last night and drove it afterwards, and all was well, ran great. Today I'm driving it back from having dinner with the family accelerating through about 70 with roughly 45 pounds of boost and all the sudden it was just like I let off the throttle, I looked back and there was a cloud of blue smoke. I shut it off immediately to prevent any additional damage to the turbo, and had a buddy of mine pull it home. I pulled the turbo off and it looks as if the shaft broke right on the turbine side of the center section. The turbine pretty much self destructed. What are the chances of getting a new turbo from BD, after all it has less than 500 miles on it and was put on the day before yesterday by a professional installer. I realize it says on their website they don't warrant products that are used in a so called "race" application, but this is hardly a race application, just a daily driver. One other thing I didn't care too much for was the fact that the installer put the turbo on, set the wastegate, and just backed the pickup from the front of his shop to the back onto the dyno and made about 7 dyno runs. Following that he was messing with the comp under load causing the turbo to bark everytime he switched the setting under load. I wonder if that didn't contribute in part to the premature failure of this turbo? Anyhow, sorry to be long winded but $800/day for turbos isn't my cup of tea especially if I didn't abuse it.





Shawn Huizenga



2001 2500 QC LB 4X4 Suncoast transmission, drag comp, BD HX-40, K&N cone system, 120hp Bully Dog injectors, 4" exhaust

 

[fj40charles]

That really stinks. The installer should not have dyno'd the truck without letting the turbol break in. Also, 45 PSI is too much. Piers HX40's are set to open the wastegate at 38 PSI. Did you talk to BD to see what they can do?

 

[shawn huizenga]

I haven't talked to anyone yet as it broke today, and nobody is around until tomorrow morning. I'll call BD and the place I had install it tomorrow morning and get the scoop on it. Also, the BD installer told me that BD recommends a maximum boost pressure of 48 psi. In my opinion that is too much, but that is their "professional" recommendation that was followed, and the boost never exceeded 48psi. Hopefully they'll help me out some on this. I can understand not warranting something for a year of abuse up and down a race track and pulling sleds, but one and a half days of empty driving is a little different story. Again, just an opinion, which may not mean much in the big picture.



Shawn

 

[BillGotthelf]

Shawn-I was told by Piers employees that the HX40 (even theirs) was not built for runs over 42lbs. They wastegate theirs at 38 and recommend you don't change it. Also they recommend a breakin period for the turbo of 100-200 miles where little boost is used. Straight to the dyno after instal and 48lbs of boost doesn't sound right at all.

 

[DPS]

I know this doesn't help much but what you have experienced is why hx-40's are not popular with a majority of competition trucks. Usually a well built hx-35 will do as good or better than a 40. I have a couple 35's we run 50-54 psi going down the track with no reliability problems, but I wouldn't sell one just because of the liability. my advice get a good "built" 35 or some variation of an HX 50 if you want duability 40's except for piers just don't hold together.

 

[HeberRam]

knowledge is valuable

Your'e probably not going to like this, it appears several things caused the failure.



#1. You don't dyno a new turbo, I don't care which kind out of the box.



#2. Proper break -in and pre oiling is essential to turbo longevity.



#3. You don't slam buttons on a comp box under extreme load or boost. This can cause damage to the vp-44.



#4. The Hx-40, I don't care whose it is, should not be pushed beyond 42 psi. That doesn't mean you lay on it all day at 42 psi.



#5. Proper setting of an HX-40 wastegate is essential, for the mods on a given truck. Drive pressure on a heavy modified truck can over come the setting to exceed 42 psi if not properly done.



#6. The way you were driving, hard acceleration pushing the truck in speed and boost 48psi, tells me you weren't just cruising at 70 MPH.



IMHO if what you said is true, both you and BD were to blame. Any knowledgeable installer, would have set the wastegate to the proper opening, would have advised you not to exceed 20psi of boost for at least 200 miles, never exceed 42 psi anytime, and the proper cool down of turbo before shut down. When you modify your truck, you better know what you're doing... . knowledge is very important and this is what I'm sharing with you. Modifications to your truck are not warranted usually by the seller. Unless you can prove BD did in fact dyno after the install, didn't properly set the wastage, and the tech said you can go to 48psi... you may have a chance for some compensation or replacement. Good luck!!!



Steve

 

[csutton7]

Folks-HeberRam isn't spinning out of control on this one---he has laid down the facts hard and simple concerning the HX40---take them to heed my friends----great job there HeberRam and fj40 is on the same page----chris

 

[jwilliams3]

Anybody that knows anything knows not to DYNO a brand new turbo charger!!

Escpecially a modified HX40!

I run my PDRhx40 up to 45lbs on a regular basis, and I have barked it hard.

I have ran it a year and if it breaks I can live with that.

2 day lifespan has to be tough on your pocket.



I would place blame with the installer and yourself for taking it up to 45 lbs of boost so early in its life.



If BD doesnt help you, I recommend you buy a "center" for you HX40 from HTT turbo. I think they are priced around 400.



Good luck...



--Justin

 

[Sled Puller]

As an outsider looking in, I would say the installer/dyno guy owes you a turbo, not BD.

 

[kentdiesel]

I agree with Sledpuller. The turbo never stood a chance with a breakin like Shawn described. I am glad I do my own work.



I have 10,000 miles on my PDR-HX40 with no problems. I think they are a great turbo for mild applications like mine. I followed Piers recommendation of not going over 20lbs of boost for 200 miles. I was told the wastegate is set to 38 lbs. but the telltale on my SPA gate has shown low 40's a few times.



Shawn,

IMO you the installer owes you a turbo if BD recommends taking it easy on their new turbo at first.



Kent

 

[shawn huizenga]

thanks for the replies guys, I just got off the phone with the installer and he said he's got a new one there waiting for us free of charge, which I think is great although I realize the blame is twofold and I should not be laying all the blame on the insataller. As for the VP-44 damage, that was rather evident as when I got home the pickup died about 2 blocks from home, checked the codes, and sure enough the death code was there. I bought a brand new one and put it on the next day. Anyway, moral of the story is the new one is getting the wastegate set to never exceed about 36psi and will be broken in properly as to hopefully prolong the life exponentially over the first one.

 

[jwilliams3]

You can run 40 psi safely.

But, make sure to break in this turbo properly.



--Justin

 

[CumminFast]

so was the installer responsible for the vp44 failure too?

 

[shawn huizenga]

Well this time around, I'll be putting the turbo on myself because it's in my shop now, and will be breaking it in very easy. As for the VP-44 failure, I didn't pursue the installer for that, and I'm not sure how to approach the situation. I just purchased a new one from him and installed it myself(once again pickup at home when it broke down). I can imagine switching settings on the comp while under load did damage to the pump but weather or not it caused the failure I do not know. The pickup has only 30,000 miles on it, and has a FASS fuel supply system so fuel supply was not an issue IMO. What do you guys think, just let it be in the past or should I bring it up to him? I am not too terribly concerned about the pump as the new one should last a long time provided it isn't abused and always has a good supply of fuel going to it, even though it was a $1900 kick in the pants also. This is yet another item that has no warranty because of the pierced pump wire. It has survived its first 100 miles of use with the pump wire pierced so hopefully its a good one. You know what they say, if you wanna play, you gotta pay!

 

[Sled Puller]

1900 was a little steep. Be nice if he would let you have it at cost, for all the trouble.

 

[shawn huizenga]

Yeah, I thought so too, but sometimes you pay for the convenience too. He had one in stock and I picked it up on a Saturday afternoon, had it in and running that evening. Cummins and all the injection shops would have had to order one in. Total was $1841 after sales tax. Right now I am satisfied with the fact that he's going help me out on the turbo so I don't think I'll pursue the injection pump deal. He's been very good to us before so I don't want to sour relations over something he may or may not have directly had an effect on. Thanks for all of your replies.



P. S. --It'll probably be a while until you guys hear from me again, I have been activated with the Army National Guard to serve in Iraq and am leaving in about a week and a half. I'll spend one year overseas, so the total will likely be about a year and three months.

 

[Diesel Gunner]

God Bless you, Shawn. And we will all pray for your safe return. And, when you get there, let everyone there know that they are in are prayers too.



God Speed!

 

[HeberRam]

glad for you

Shawn... I'm glad you were able to get a replacement turbo. As far as the VP-44 is concerned, it would be impossible to prove what he did killed the VP-44 pump, however, it didn't help... Two things to provide longevity to your VP-44 pump is to make sure you have adequate fuel pressure and a gage to monitor it. And secondly, when running your comp box don't change settings on heavy load or high boost. If you feel you need to change settings"on the fly" let off throttle to zero boost, change setting and throttle up.



Good luck, and keep safe.



Steve

 

[BillGotthelf]

Hey Shawn do you need someone to watch your truck while you are away? I'm available . Good Luck and watch your 6.

 

[propuller]

Originally posted by Sled Puller

1900 was a little steep. Be nice if he would let you have it at cost, for all the trouble.

Thats what i was thinkin.





Kurt