Turbo Failure in 2004.5 & 2005 2500/3500 Trucks

[JCarlisle]

I am looking for anyone who has had any kind of Turbo Failure on one of these Trucks. One common Thread in this is that the 5 I know of so Far all had exhaust Brakes usually a PAC Brake but Mine has had a Failure with Both a PAC and a Jake ( 5th Turbo is going now). My Truck is Stock except for an AFE stock replacement Air Filter and a Muffler eliminator Kit.

The Service Manager at my Dealership is Trying to solve this Problem and He has treated me excellent He would like Vin Numbers of Trucks experiencing the same problem. I would like to put anyone who is experiencing this problem in touch with him and I will help you with this connection.

If you have experienced or are experiencing this problem now, answer this post and I will get in touch with you and give you his Contact Info and let him know that you will be calling.

Thanks for the Help

 

[BEmmert]

Don't know if you looked within the last posting you had, but my 98. 5 has been experiencing the same problem with a PacBrake. I contacted PacBrake and they gave me the same song and dance about how it can not be the brake and that it might be high exhaust temps at the top of a hill when it gets turned on and so on. They also stated that far as they knew I was the only one with a 2nd gen to have this issue. I have a sneaking suspicion that there are many more of these trucks out there with the same problem, but its just that guys most often don't go pulling the boots off to check for oil in the cooler. Mine had got to the point that it was leaking out around the boots, that's the only way I knew about it. If you really want my info I can PM you, but I am sure it wont do much good to finding the problem on your motor.

 

[BMHenry]

Please help

I have an 05 3500 6spd with jacobs exhaust brake. . I just blew my turbo at 99,508 miles... The district manager says this was the result of a "clogged" airfiter. . I have the same set up with an AFE Pro Guard 7. . They said that they would not warrenty the motor due to this. . They also said that it needs a long block ect. . Please help. . I have tried to plead my case with them with no luck. . The only test done on the air filter was a visual inspection. . ... There was also a chip on the motor (gas milage) but took it off about 2 yrs ago, no chip on it when it was towed in to the dealership. . They also said since it was chipped it voided the warrenty... Please,:{ if anyone can help me on this it will be greately appreciated. .

 

[jelag]

We've been installing PacBrakes on many different engines over the past 20 years... I can assure you that the factories that approve engine brakes and exhaust brakes, (Cummins, CAT, etc) wouldn't approve them for their engine groups if there was an issue with the exhaust brake causing turbo charger problems...

I've personally owned enough Fords and Dodges with pacbrakes in the past 15 years to accumulated 3 million combined miles with no problems... we usually sell the truck with 500K miles on the engine... . We've never had to replace a Turbo... .

Turbos do fail... that's why there's a group of rebuilders in the country that rebuild them... If you go to any truck shop on a given week... there is usually a truck in the bay for some engine work and that usually means Turbo work as well...

I do suggest that there is an underlying cause for the failures... . and examination of one of these turbos by one of the excellent rebuilders will lead to the cause of the failure... We rebuild HD clutches, Fan Clutches, Air Compressors and other products. . I can tell you without a shadow of doubt that we can nail the failure of an Air Compressor or Clutch with a few simple questions and looking at the product. . Often the customers doesn't like what he hears and tries to push the blame somewhere else...

I've also learned that the parts changers in most dealers, and truck dealers don't have a real clue how something functions in and around the system its installed in... .

Remember that the exhaust brake can only come on when the engine is at idle and the fuel system is its lowest fueling point... . also remember that the ECM has placed a 1-3 second delay in the ""turn on of the exhaust brake"" to allow for reduced fuel pressure in the fuel rail... .

I'd be more than willing to explain the operation in more detail... if you'd like or answer your exact questions regarding the operation of an exhaust brake. . But you give no logic as to why you think the exhaust brake is causing the issues...

BTW, please note the ages, mileage of the trucks listed below... the last time I posted my phone number I got in trouble... but feel free to email me and I'll give it to you...

 

[AH64ID]

I contacted PacBrake and they gave me the same song and dance about how it can not be the brake and that it might be high exhaust temps at the top of a hill when it gets turned on and so on.

I cannot speak for the Pac, but the Jacobs does hit much harder with higher EGT's. It will hit the peak, 63psi, about 3-400 rpms sooner, but it still peaks the same...



My response to Pac would be "So you designed it not to be used on trucks that tow?"

 

[JHofmann]

I had to replace the turbo on my 03 due to it pushing oil into the cooler. Only 55K on mine, probably 25k with the Pac brake on it. I repalced it with a HE351 from an 04. 5 and up truck. We'll see how this one does?? It was new when I installed it.

 

[HBarlow]

We've been installing PacBrakes on many different engines over the past 20 years... I can assure you that the factories that approve engine brakes and exhaust brakes, (Cummins, CAT, etc) wouldn't approve them for their engine groups if there was an issue with the exhaust brake causing turbo charger problems...

I've personally owned enough Fords and Dodges with pacbrakes in the past 15 years to accumulated 3 million combined miles with no problems... we usually sell the truck with 500K miles on the engine... . We've never had to replace a Turbo... .

Turbos do fail... that's why there's a group of rebuilders in the country that rebuild them... If you go to any truck shop on a given week... there is usually a truck in the bay for some engine work and that usually means Turbo work as well...

I do suggest that there is an underlying cause for the failures... . and examination of one of these turbos by one of the excellent rebuilders will lead to the cause of the failure. . . We rebuild HD clutches, Fan Clutches, Air Compressors and other products. . I can tell you without a shadow of doubt that we can nail the failure of an Air Compressor or Clutch with a few simple questions and looking at the product. . Often the customers doesn't like what he hears and tries to push the blame somewhere else...

I've also learned that the parts changers in most dealers, and truck dealers don't have a real clue how something functions in and around the system its installed in... .

Remember that the exhaust brake can only come on when the engine is at idle and the fuel system is its lowest fueling point... . also remember that the ECM has placed a 1-3 second delay in the ""turn on of the exhaust brake"" to allow for reduced fuel pressure in the fuel rail... .

I'd be more than willing to explain the operation in more detail... if you'd like or answer your exact questions regarding the operation of an exhaust brake. . But you give no logic as to why you think the exhaust brake is causing the issues...

BTW, please note the ages, mileage of the trucks listed below... the last time I posted my phone number I got in trouble... but feel free to email me and I'll give it to you...

Jelag, there's a lot of wisdom reflected in several of the comments in your post above.

Both my prior Dodge-Cummins had Jacobs Exhaust brakes from day one but I've never owned or used a PacBrakes so can't enter into the discussion there.

But I will say that I'm already on record as suggesting to the original poster that there is little to no chance his dealership service department is even going to stumble upon the cause of his problem. Even if they stumble upon it by accident they won't recognize it.

He needs to haul his truck away and find someone who understands the related issues. I would be afraid that eventually Chrysler, a company with severe financial troubles, is going to cancel his warranty to cut their losses leaving him with an unrepaired and unreliable truck that may only have a minor problem that can be cheaply and easily fixed.

Your suggestion about finding a highly skilled turbo rebuilder is the best suggestion he's received yet. I would follow that advice at my own expense rather than continue wasting time with the parts changers at his local dealership. And, as you wrote, the OP may not like the answer when he gets it.

 

[jelag]

Harvey...

Thank you for your kind words... I often struggle to keep my thoughts to the facts the best that I know them and find answers to questions I can't answer from engineers...

Cummins sets the maximum working pressure of an exhaust brake on our trucks at 60 psi... any more than that and excessive pressure will push the weakest exhaust valve open at the wrong time and it will strike the piston. . I've seen 2 examples of this in 15 years where the owner of a brake reset the hole in the valve or spring pressure without the correct/proper specifications... That's why we only sell brakes that are factory set, or if we use, say a 5 " brake as an inline brake we see to it that PacBrake has factory flow tested the brake and set it... . without a dyno or flow tester this is very hard to do.....

To be honest I've accepted PacBrakes word on the pressure... . as they are the engineers... and the guys who built the direct mount design and later put the patent on it.....

I own a 10 L Cat engine that won't accept an engine brake and pacbrake tells me that if I change the valve springs to accept an exhaust brake that we can expect the hard surfacing on the cam to go away... . it was just never designed for either brake... so I have 1 truck that I don't care to change the cam in... . so it runs without a brake... The key here is the engineering and the science... .

 

[AABEN]

I am looking for anyone who has had any kind of Turbo Failure on one of these Trucks. One common Thread in this is that the 5 I know of so Far all had exhaust Brakes usually a PAC Brake but Mine has had a Failure with Both a PAC and a Jake ( 5th Turbo is going now). My Truck is Stock except for an AFE stock replacement Air Filter and a Muffler eliminator Kit.

The Service Manager at my Dealership is Trying to solve this Problem and He has treated me excellent He would like Vin Numbers of Trucks experiencing the same problem. I would like to put anyone who is experiencing this problem in touch with him and I will help you with this connection.

If you have experienced or are experiencing this problem now, answer this post and I will get in touch with you and give you his Contact Info and let him know that you will be calling.

Thanks for the Help

Do you pull a large loads? you need to tell us more about it and you driving habets