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I am having my turbo replaced under warrentee by my local Dealer, so far they have had it two days, with today being the beginning of the third.



My question is how long should it take to remove a stock turbo out of an 2006 3500 and replace it with a new one? The Service Manager told me I would get it back yesterday, but it's not done yet.



I thought it was pretty straight forward, not too complicated, but then again I don't know what is involved in the replacing of a turbo.



Thanks in advance.



Tom
 
It should take a couple hours,but if the shop is back logged or if they received a damaged or wrong part... ... ... ... ...
 
When I was accelerating and the turbo, according to my boost gauge was at about 26 - 28 or higher, and I quickly let off of the accel. pedal, it would make a rattling/grinding noise. At the same boost levels, when I let off of the accel. pedal slowly, it wouldn't make any noise. Does that make sense?

I took it in to the Dealership and they said it was a bad turbo. They called and said it was covered under warranty, I didn't ask what was wrong with it over phone. Figured I'd do that when I went to pick it up.
 
I'm going to guess that the turbo is not a stock part and requires authorization for replacement and it will have to come from a parts depot. .

You don't say where your at... . but a diagnosis late in the day, and approval late or the following morning plus shipment time from a depot now we're at 2 days... and lets assume they have heavy freight traffic from the holidays... ... catching up with Christmas or like here in the Northwest, closure because of excessive snow and road conditions... what ought to be a couple of days could turn into 3 or 4... .

But bob4x4 has a great point... . a turbo on an 06 is very rare... wonder what the real cause of the failure is...
 
Actually, there have been several turbo failures on 2006 trucks, also 2007 trucks, mine failed right at 50K and was replaced under warranty. Most dealerships DO have one on the shelf, but some do not. It took the fellow at my dealership 2. 5 hours to r & r my turbo.



Mine had similar symptoms to what you have described, also an infrequent squealing sound, had a lot of side to side play and in and out play, there was ecidence of grinding on the housing.





CD
 
I've put a lot of miles on three Dodge Rams and never replaced a turbo. I wonder if those who have had failed turbos allow cool down time before shut down after running hard?
 
Now, now, that's not fair . . I do admit that I am anal about stuff, but, when it comes to how expensive stuff is, I'd rather be anal than broke. And, I'd rather spend my hard earned cash on mods, not replacing stock parts with stock ones that have failure rates that should not be. We see that also with those poorly designed injectors and fuel related issues, but it does lend itself to doing performance mods, and once you have gotten into those, your truck will be much better and you will be much happier.





The first addition I made at a couple days of ownership was to add gauges. I have from day 1 of ownership taken the time to make sure my turbo is cooled down, I do not shut down until my EGT's are right at or under 300*s, and usually more like 275*s. I also change my oil religiously, have a bypass filter, oil cannot be in better condition when being drained as compared to a lot of people I know. I have run the factory recommended Valvoline Premium Blue, and I oil test at each change (more of that anal stuff). My test results have always been excellent, so no contributing factors like silicone or soot.





Maybe living/driving at high altitudes is harder on turbos?? I am at 7K ft elevation and drive a lot up to 10K ft elevation, but also go down to 1500ft elevations a lot too. While at high elevation our summer temps are right around 80*s, when I am running around at the low elevations I easily am driving a lot at 105-110*s, and that could play a role also. And then comes the towing, I do a lot of towing, and more often than not the loads are right at 18K or more with many steep grades.





I guess the 325 engine is a little different in performance demands than it's predecessors, I do know that there are quite a few differences in the factory programming, maybe that has to do with it too?? Plus, in the first year or two my dealership made sure I was getting all the latest flashes, their explination was that they were getting the bugs out of stuff that was problematic to performance. When I think about those turbo failures that I know about, all of them are people who tow a lot and also tow heavy, maybe they needed to use a different turbo?? and I wonder how that 3rd injector event might play a role??





I did notice that the new turbo sounded very different than the original one, actually quite a bit different. I can also say that my EGT's have always been somewhat high, or higher than many others report when discussing them, and reading threads seemed to me that many of the 2006 owners were experiencing the same. And also, it seems like more 2006's and 2007's have melted pistons more frequently also.



The high EGT's have always concerned me, so much that I went to twins to get them under control, and the twins DID bring them down considerably. Less gauge watching now, less worry, and hopefully more longevity, since we all know that excessive heat is what does engine life in the fastest.





My dealer told me that they had many 2006 trucks with the same type of turbo issues mine had, probably was some kind of mfr defect since the numbers were fairlly high. Since my local dealer is also at high altitude, maybe they were referring to the local trucks?? That would make sense since most that I know who have had issues are my fellow locals. But there have been others at much lower altitudes with this failure also, one fellow was told ny his dealership that his PacBrake was responsible for his early failure. If the PacBrake caused it, then I would say that any exhaust brake could cause it, and I wonder how many factory brakes have been responsible too.









TCDiesel - do they make turbo wax ?? . . might have to get me some, eh?



CD
 
I picked up my truck yesterday, with a replaced turbo on it. As I was driving home, my truck made the same noise that I described above. I turned around and drove back into the dealership. I went in to speak to the service mgr. and told him the noise was still there. A tech was standing there with the mgr and he told me to put the stock air intake on. I am running a aFe Bruteforce intake and have been for the last 45,000 miles. The service mgr. told me that the intake was the cause of the noise. I asked if he would at least come out and listen to it, and he told me that there was nothing they could do for me. Needless to say, this upset me, long story short, he went on a drive with me and he heard the noise.

Service mgr. kept repeating several times to me that "we did replace the turbo". It's like he thought I didn't believe him.

Anyhow, it was 3:30pm on New Years eve, so I just told him I'd call next week to speak to him more about it.


Jelag, I wonder what the real cause of the turbo failure is too. After towing heavy or running hard, I always allow cool down time of about 3 - 5 minutes or so. Maybe I need to increase that?
 
I picked up my truck yesterday, with a replaced turbo on it. As I was driving home, my truck made the same noise that I described above. I turned around and drove back into the dealership. I went in to speak to the service mgr. and told him the noise was still there. A tech was standing there with the mgr and he told me to put the stock air intake on. I am running a aFe Bruteforce intake and have been for the last 45,000 miles. The service mgr. told me that the intake was the cause of the noise. I asked if he would at least come out and listen to it, and he told me that there was nothing they could do for me. Needless to say, this upset me, long story short, he went on a drive with me and he heard the noise.



Service mgr. kept repeating several times to me that "we did replace the turbo". It's like he thought I didn't believe him.



Anyhow, it was 3:30pm on New Years eve, so I just told him I'd call next week to speak to him more about it.





Jelag, I wonder what the real cause of the turbo failure is too. After towing heavy or running hard, I always allow cool down time of about 3 - 5 minutes or so. Maybe I need to increase that?



Sounds like you are just barking the turbo... put the ECM back to stock and see if the issue goes away. .
 
Bgpig.



Do you have gauges? After a long hard day of towing it does take a while for the temps to come down. I have never timed the cool down time, usually I leave the truck idle while I get disconnected, have no idea how much time I spend doing that. And I see, you also tow, so maybe the turbo is NOT enough to handle the 325 engine and our demands?? Maybe we are cooking it more during run time?? Oil temps would reveal what our operating temps are and whether the turbos design is being stressed??



All your aftermarket intake does is let you HEAR your turbo better and drive it a little more with air flow. They probably have figured out that if more people add aftermarket intakes they will hear their turbo operating, and have it more into it's range limits, plus we spend more time in our towing gear, so higher rpm's. Maybe that's more the reason they make such a big deal about aftermarket intakes, they might have more who would have warranty replacements . . .



CD
 
When I was accelerating and the turbo, according to my boost gauge was at about 26 - 28 or higher, and I quickly let off of the accel. pedal, it would make a rattling/grinding noise. At the same boost levels, when I let off of the accel. pedal slowly, it wouldn't make any noise. Does that make sense?



I took it in to the Dealership and they said it was a bad turbo. They called and said it was covered under warranty, I didn't ask what was wrong with it over phone. Figured I'd do that when I went to pick it up.



Are you sure that you aren't trying to describe "turbo bark" ?? I did this kinda frequently when towing up big grades under full power until I learned how to drive a TB... You have to let off the go pedal gradually instead of all at once...
 
Wingate and LRutigliano, I've never heard of "turbo bark" is that like the chocolate pepermint bark they sell at Costco :) ? Just kidding, could you explain that to me a little more or tell me where to go to find out more about it? I usually let off on the accelerator slowly. When I first discovered this noise, I was passing a slow car on the interstate and they pulled into my lane right infront of me so I had to let off the accel. abruptly. After that, I tried to get the truck to make the same noise and found that I could. I've had 4 diesels in the last 10 years, (two 7. 3 powerstrokes and two 5. 9's) and thought I knew how to drive them, maybe I don't.

CD, I do have gauges, but don't have any for oil temp. I do tow, but it is usually an aluminum 3 horse trailer with 2-3 horses in it. I think I'm right around 10K with all the stuff and horses. I am like you, I usually keep the truck running when I unhook to let it cool. In my ignorant opinion, I think the service mgr. and tech were just trying to get me out the door yesterday.

Again, thanks for everyones imput, I appreciate it.
 
When I first discovered this noise, I was passing a slow car on the interstate and they pulled into my lane right infront of me so I had to let off the accel. abruptly. After that, I tried to get the truck to make the same noise and found that I could.



Again, thanks for everyones imput, I appreciate it.

Pretty sure what you are describing is what lots of people refer to as tubo bark... It usually stems from having the boost up like during sudden accelleration then dumping the throttle, the turbo is spooled up and the inlet air system is pressurized, suddenly you loose all drive pressure on the turbo and it almost wants to stall the shaft out on the turbo. You probably never heard it on the old 7. 3L due to them not being capable of building 32-34psi in stock configuration. . while it might happen on the 7. 3L there just wasn't enough air pressure to make it audible. It usually shows up after an intake mod and/or aftermarket programming. It appears as though you have both...

I would unload any programmers etc and try it again... the noise MIGHT still be there, but should be lessened... Installing the factory inlet air piping/filter should in combination with the factory programming should silence it all together.

Be careful to limit how often you put the turbo in this condition, it can possibly do damage to the cartridge assembly.
 
Under 30 psi there should not be any bark or noise when the throttle is lifted abruptly. Now, if boost fooling is working and the ECU is not controlling the WG thats a different story but still doesn't usuaslly show until you push past 30 psi.



True turbo bark is a WUMP under the passenger floor board like light a propane torch with too much gas on. What he may be hearings is the surge that happens when the compressor doesn't fully stal but slows and speds several times. That tends to make a lot more noise like a rattle.
 
So if the noise I am hearing is Turbo Bark or Surge, is this normal? I was running the Smarty 30 hp download. Unloaded it before I went to Dealership, and could still get it make the noise.

Million Dollar (or at least maybe a couple thousand dollar) question, do I have anything to worry about?
 
Completely stock, I would have to say the noise is NOT normal.



Experience with my truck, no back or surge until one loaded SW3 or higher. Then it was only bark when the throttle was lifted too fast at high rpm's or the TC locked under load.
 
Completely stock, I would have to say the noise is NOT normal.



Experience with my truck, no back or surge until one loaded SW3 or higher. Then it was only bark when the throttle was lifted too fast at high rpm's or the TC locked under load.



With my '03 completely stock (before injectors, Smarty, air intake, exhaust, etc... ), I remember going up HWY26 (Mt. Hood) pulling the 5er under full power and having to abruptly lift off the throttle due to someone cutting me off in the right lane and I just about wet my pants when I heard the turbo "bark". I thought I broke something for sure... Did it quite a few times before I understood what it was and how to limit/prevent it.
 
So if the noise I am hearing is Turbo Bark or Surge, is this normal? I was running the Smarty 30 hp download. Unloaded it before I went to Dealership, and could still get it make the noise.



Million Dollar (or at least maybe a couple thousand dollar) question, do I have anything to worry about?



1) It is normal.



2) Stop doing it or you could have something to worry about. (broken turbo shaft)
 
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