sanity check: new turbo… oil in intercooler

[Gifu]

Hi all…
11/2005 ram 2500 with 5.9
When I bought truck six months ago I noticed oil seeping from intercooler piping.
So… I replaced the turbo. I’ve driven it about 2500 miles since. ( It’s been in the shop getting the 6-speed rebuilt. )
Now I’m on a road trip and it’s smoking heavily out the tailpipe. And eating oil. A 1/2 quart per tank or so.

The turbo shaft has zero end play. And boosts well (minus the smoke).
The exhaust is blowing blue smoke at idle that smells like burning oil but only seems to do it after a run on the highway… then alternating blue then white smoke under acceleration. My theory is that the turbo is leaking a small amount of oil into the intercooler. Under heavy load that oil is mostly burned well by the engine… but at stop lights the heavily oiled intake is causing heavy smoking.
It’s intermittent. Some stoplights it’s smoking like a grandma playing bingo… and other times it’s smoke free.
this 5.9 has a simple CCV (no PCV) system that does not send any vapor to the air box or turbo inlet but rather it vents to atmosphere above the axle. If it was a cracked ring the crankcase pressures would cause the CCV to blow tons of oil all over the axle. But it’s dry.
… so the only place I can see it getting oil into the intercooler system was the turbo.
Pulled the intercooler tube near the turbo outlet and it’s very oily.
Turbo manufacturer says they’ve sold 2000 of these turbos and they haven’t had one go bad.
Ideas? Thoughts? Jokes?

 

[Gifu]

Made it home 500 miles… and three gallons of oil.
It “must” be the turbo, obviously… but is there anything that can cause a turbo oil seal to blow besides age or poor manufacturing?

 

[bcbender]

Id stop driving it before you end up with a runaway, that is alot of oil if you are feeding the engine directly through the intake system. I'm sure someone will chime in, but it sounds like the turbine shaft seal but Im no expert on turbos. Quick thoughts: I assume your turbine housing oil return line was clear and not blocked, Intake Air filter is clean and not restricting flow?

 

[Gifu]

Yes now that I’m home… it’s parked.
The local rebuilder mentioned checking the return line, air filter, and blow by.

 

[BigPapa]

Id stop driving it before you end up with a runaway

THIS.


I'm assuming you've been checking the oil level. I've seen posts here that if the oil level is too high the oil covers the end of the turbo oil drain.

 

[Gifu]

The oil level is always low because it’s eating oil so fast! Hahaha. Ahem.

 

[BigPapa]

I wonder if it has the correct dipstick in it or something. Have you changed the oil and put the correct amount back in it to know if the dipstick is reading correct?

If it has the wrong dipstick in it and it's too short, you could be overfilling it.

 

[Tuesdak]

Turbo manufacturer says they’ve sold 2000 of these turbos and they haven’t had one go bad.

SO WHAT?! Are they going to warranty it or what? I would also ask for reimbursement for the oil it burned. You need to clean out the intercooler or the next time you romp it with a good turbo the oil sitting in it can run the engine away.

 

[GrantP]

2000 turbo's and not a failure...well...first time for everything. Nobody bats a 1000 forever. Pull it and send it back before any real damage is done.

 

[Gifu]

Well that’s an interesting theory.
I mean… this truck has been through the ringer with previous owners. Engine was “rebuilt” but have no records or ideas what that means. I’ve found lots of hokey sh** done to it.
the dipstick “looks” correct.
I’ll see if there’s a part number on it.

 

[BigPapa]

If it were mine, I'd drain the oil, change the filter, put three gallons of oil in it, and check it on the stick. That way you're SURE it's reading correctly.

Is the engine the original engine that came in the truck? You can post or PM me the VIN and the ESN and I can tell you.

 

[sag2]

With that much oil going through it I'm surprised you haven't had a runaway already. Especially when idling, the oil will pool in the intercooler. When you get on the throttle hard all that air pulls the pooled oil into the intake, and away she goes.

 

[Gifu]

Right? Scary. I think because she was running full steam on the freeway so the oil never pooled enough?
Tearing into her tomorrow.

 

[Gifu]

Circling back in this thread. Life got in the way.
Ok sooo couple things.
Smoking gun: oil return line on my rig had 4-5” of soft hose to connect hard line to a large nipple in block. The fine gentleman (insert eye roll) who installed this turbo for me, managed to twist and collapse the 4” of silicone hose!!! (Face palm)
This of course cause the oil drain to back up and spill into the cold side and fill the intercooler.
Two turbo shops heard my story and said… run it. Probably no damage done.
these don’t have an oil “seal” but rather more of a “piston ring” as they called it.
While life was distracting me I had my stock turbo rebuilt…
So now which should I install???? The aftermarket “tow” turbo that had a bit more power and is fancier… but still maybe might blow oil? Or the stock rebuilt job? Opinions? Stories? Anecdotes?

 

[AH64ID]

Pull the intake plumbing, get it 100% cleaned out, and reinstall it.

Drive it and see if it still eats oil.

What brand/model of turbo?

 

[Gifu]

To be clear… They are both off the truck.
Stock rebuilt turbo and a “Ryan’s Tow” turbo

 

[Timd32]

Anecdotes

Do they make a sight glass adapter for the 4" hose?

I would run the Tow turbo, might as well.

 

[BigPapa]

I agree with John and Tim. Run the big turbo. You found the problem and fixed it. Get all the oil out of all the CAC piping AND have the CAC cleaned out. Cheap insurance for your safety and to keep from replacing, at the least, and engine in the event of a runaway.

A friend of mine actually blew a turbo on his D-Max and put oil in the CAC and pipes. He put a new turbo on and drove the truck. The first time he got on it and built some boost it ran away on him. He couldn't stop it or hold it back so he popped it into neutral and let her go.

 

[Gifu]

Geeezo. That’s scary. it’s crazy it didn’t run away before… considering it ate 3 gallons of oil in 500 miles.
the intercooler sat upside down draining any residual oil for two weeks. It’s pretty cleaned out.

 

[AH64ID]

Draining is not enough. It should probably be hot tanked.