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Turbo failure warning on some 24 valve...read!

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After reading about the problems some of our fellow TDR boys have found with turbo blades being chewed up on their new 24 valve trucks, I have this to offer.

As most of you are well aware of I work for CAT. About 6 months ago, give or take a few months, we started having turbo failures on some holset turbos (we use 4-5 different turbo suppliers depending on application). We had 4 gensets fail out in the field due to turbo blades grinding the aluminum housing up until the shaft locked and broke.

This caused 3 of them to catch fire, one was a genset for a hospital, and the other was out in B. F. E. , and the other 2 we lost in house during testing.

Rumor had it that Holset had just got a new factory going in Mexico and the quality checks were not where they needed to be. They did get things squared away down there I understand. I said something about this to the Holset guy at Schieds diesel fest thing and he didn't want to talk about it. Said it was fixed.

I urge everyone to go out and check the clearance between the blades and the inner aluminum wall. Some of you that have hot EGT's due to bombing could be worsening the situation because the metal will expand on the blades, and might cause more wear. If that impeller shaft breaks, oil goes everywhere and a serious fire could result, so get off you a$$ and get outside and check things out. It might save you more than you think.

I am posting a copy of this message in a few other places on the board, hoping it will get some visibility. Moderators, please dont delete or lock these copies from the other discussion forums, this could be a very serious situation.

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Always ready to help!
2000 2500 Red Sport quad cab, 4x4, K&N, DDI's, straight piped, boost, pyro and fuel pressure gages, Hot Power Edge, EZ box, mean looking set of 33. 5" tires, Snap On diamond tool box, Marine Corps window sticker, Semper Fi!

1972 340 Cuda'. Original tripple Black, 340 car w/air. Good clean car, super stock springs, Weld Prostars, shaker hood, strong 340 with a 727/4000 stahl, 4. 56... . Bombs away!
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Chad, how do you check the clearances, and how much clearance does there need to be?? Since it is not feasible to check the exhaust side, will checking the compressor side suffice??

Vaughn

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'01 2500 QC Shortbed 2wd, 6-speed, 3. 54LSD, Cab & Fog lamps, Camper & Tow Pkg.
BOMBed: RV injectors, PS Boost module, Amsoil air filter, straightpiped exh. , SS fuel lines, AutoMeter Sport Comp gauges, Amber turn signals conversion
 
Yes, the intake side is what was rubbing. They try to keep the clearances tight due to emisions and such.

A little trick I used was I took the intake side to a fairly warm turbo and inserted a business card between the blade and the aluminum wall. The ones that were labeled "bad" at the plant by measurments taken with mics by the engineers, barely would allow a card to fit. The ones that were good I could take a business card and slide it in between the blade tips and the wall with almost nothing touching the card.

I dont know if this "trick" would aply to our turbos being how small they are. The turbos at work require a hoist to bolt to the engine.

I do know the fix was to machine 5 thousandths off the aluminum intake housing wall.

Another thing we noticed was on some the aluminum side housing was canted a little bit in that clamp that hold the two housings togather (intake and turbine side). We had to loosen the clamps up and make sure everything was square before we tightened everything back up.

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Always ready to help!
2000 2500 Red Sport quad cab, 4x4, K&N, DDI's, straight piped, boost, pyro and fuel pressure gages, Hot Power Edge, EZ box, mean looking set of 33. 5" tires, Snap On diamond tool box, Marine Corps window sticker, Semper Fi!

1972 340 Cuda'. Original tripple Black, 340 car w/air. Good clean car, super stock springs, Weld Prostars, shaker hood, strong 340 with a 727/4000 stahl, 4. 56... . Bombs away!
NRA Life Member
My Diesel Page

[This message has been edited by Chad Sheets (edited 02-06-2001). ]
 
The guys over on 24 valve engine forum that reported the problem have brand new truck I believe. I doubt it is a big quality problem. Just a few that got through the loop, like we had. I just wanted to let everyone know what I have seen happen with the same type situation in the past. Cant be having my TDR buddies trucks catching on fire.
 
Are you talking intake impeller side or exhaust side clearance. Sounds like intake side with description blades and Alum. housing. Why would high egt effect intake blade clearance. Is there that much heat transfer? What gives. Thanks

2001 3500 6sp cummins
 
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