Nothing like ruining two turbos at once!

[Tinman]

I finished installing an ATS Aurora 5000 twin turbo kit a few days ago. I took a few test drives and all seemed well except an oil leak b/o not getting one of the drains lines tight enough. I was looking for a way to install my oil temp sensor (since the stock turbo needs that port) and I took off the intake to the stock turbo. I nearly puked. Compressor in shown below. Ruined. Checked the 5000 turbo. Same but not nearly as bad. Some how, a piece of something got in the intake after the filter and before the bottom charger. I have no idea what or how. I'm very careful to be clean so this kinda of thing won't happen. (obviously, not careful enough). I'll give ATS a call Tues. to get some parts on the way. But my question is, did the metal fragments ruin my engine as well? What to do now? I only drove a total of 28 miles since install.

 

[WCPoe]

WOW, sorry to see that, Tinman. It looks like something substantial did that damage. Certainly wasn't a paper towel or shop rag that got sucked up. Please let us know what your further investigation reveals.

 

[Wingate]

got any tools, bolts, clamps missing? What ever it was is either already gone or still in the intake tract...

 

[Slow Six]

Tough luck. That is not nearly as bad as the turbo on my 03 when the snap ring that holds the silencer in place broke and pieces starting feeding into the turbo. I was towing at the time with my big foot in it as I was passing a Furd. As I was on a busy highway I had to go a ways before I could stop and see what was making all the noise. I pulled the hose off the turbo and all I could see was carnage. I cleaned out the pieces, put it back together and started down the road. It was still making decent boost and noise wasn't to loud if I used moderate pedal. Since boost and EGTs were normal I went the last 100 miles home. Ordered a new turbo, cleaned all the hoses and intake plus washed out the intercooler. I didn't find any debris any where. Installed turbo and put truck back to work. I checked oil quite often. Engine was still running strong years later when I traded for my 2012. I'm guessing you should be okay other than a lighter wallet.

 

[Tinman]

How did you clean the intercooler? This was late yesterday, so I'll go looking for the culprit later if it doesn't rain. The cartridges and turbines will be fine. I'll definitely need new compressor wheels and maybe housings. Hopefully this can be done while mounted. I'm mostly worried about metal in the engine and damage thereof.

 

[cerberusiam]

You don't clean an IC you replace it. You would have to remove the tanks and have it rodded out to remove the metal and even then it is iffy if it will all come out.

Depending on how large the pieces were they are all probably in the IC. The finer stuf may have made it to the engine but its a good bet it didn't.

 

[Tinman]

I finally got the IC off and to my surprise, nothing came out. I can't find the culprit anywhere. I expected a piece of something fall out of the IC intake when I turned it up but nothing. I even beat on the end with a rubber hammer to try and dislodge something. Nothing. I still have no idea as to what go in there. I took off the intake horn and much to my disappointment, there was a little glitter in the pendulum at the window. I have the 5000 on it way to ATS, I just got a used he351 for someone over at Cummins Forum, New IC on the way, daily prayers to engine gods. Anything else to do?

 

[MChrist]

What is the "pendulum at the window"???

Anything on the intake grid heater?

 

[Tinman]

That's what I meant. Took the intake horn off and grid heater out. I could look in that "window" where the heater sits and could see a little bit of small debris. I am going to take off the pendulum cover and make sure it is as clean as possible.

 

[SRadke]

I roached a top turbo much worse than that once. Flush the intercooler well, replace your compressor wheels and you're good to go. The housings will polish up and run fine and the engine will swallow an amazing amount of aluminun with no ill effect. Steel would be a diffrent story.

-Scott

 

[SRadke]

Oh, and find whatever is in there and get it out!

 

[Tinman]

Not a darn thing. I took apart the intake to the valve runners (took off the intake pendulum), took the IC out and turned it up, shook the crap out of it, tapped it with a hammer and nothing came out. Nothing it any of the tubes. Checked the inside pleats of the air filter (If something were in there as a source, it would obviously be gone but maybe some other debris could have been there. ). Nothing. What I thought was metal in the pendulum with the horn off may have just been some of that silvery stuff on the horn gasket. So I still don't know what happened. Anyway, I couldn't find a satisfactory wheel and housing so I just bought a lightly used complete turbo from a guy on Cummins Forum, that way every thing is balanced and ready to go. 5000 is at ATS now. I would worry about metal in the IC so, whether I need to or not, I have another one on the way. I changed the oil and cleaned all the tubes. So I just need to get all the parts and put it back together. I guess I'll never know what caused it.

 

[BGlidewell]

could the add-on turbo have craped all over your old one?

 

[Tinman]

I don't think so. The 5000 had the leading edges of the compressor wheel damaged and the housing ahead of the wheel (as if something bounced around in there). Seems something was ahead of the bottom turbo's intake air stream. I suppose the 5000s compressor wheel could have had a defect and lost a piece getting bounced around in the compressor before being spit out to the stock charger. I think that would be unlikely and I didn't see anything that looked liked that. A big thumbs to ATS as they replaced the compressor under warranty. They cleaned it up, repainted it and it is on its way for just shipping.