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***TURBO WARNING***Read and heed!

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Brake Noises

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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!
NRA Life Member
My Diesel Page
 
chad, from what ive read tonight, the problem stems from the mexico relocation. my 2001. 5's came from the st louis factory. will they have the same housings coming from mex?
 
I think he is saying the manafacture of the turbo, was having problems with there plant in Mexico, not the Dodge plant in mexico

Originally posted by packman:
chad, from what ive read tonight, the problem stems from the mexico relocation. my 2001. 5's came from the st louis factory. will they have the same housings coming from mex?
 
Yes, its the actual turbo that was assembled/tested whatever in Mexico. Doesnt matter where the truck was made.

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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
 
Chad, Do you know the production dates of the trucks that would be effected by this defect??

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2001. 5 2500 4X4, QC, Auto, 3. 54 LSD, SLT, SWB, Trailer, Camper & Snow plow Packages, White, 35k# Cody Hitch, 20' Gooseneck Lowboy flat-bed Trailer.
 
No. I was just reading some complaints on a different thread about chewed up turbo blades, and a light went off in my head... . The kind that says, "hey, I've seen this problem before". I plan on doing some asking around with the rework gurus and see if the remember any of the details.
 
Chad, We've only had our 3500 since Nov. '00
and on top of the changes in driving and maintenance the Cummins requires now we have to deal with the posibility that the turbo may be suffering from inadequate "quality control" leading to some potentially catastrofic engine and/or safety issues!!
Except for gauges, we plan to keep the Ram stock. I would think that a turbo problem would be covered under warranty. I just don't think anyone needs that kind of a problem while towing, hauling or on a camping trip. Any and all information you can come up with will be greatly appreciated. In the mean time, how do I check the clearance of the turbo blades? Do you think DC may come out with a recall????
Thanks

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White 2001, 3500, Auto,3:54,QC,2WD,LB,34' DBL slide Cardinal 5er
 
Chad, I bought my '01 in Sept, '00. The whole truck, unfortunately, was assembled in Mexico.
How do I check the clearance?

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Shane Oler
'01 2500 4X4, ETH/6 speed, Pyro (pre-turbo)and Boost Pillar mount, Dark Garnet/Camel, 20K Reese 5er hitch

Other: '70 Olds Vista Cruiser 455 (future resto project)
30' Sandpiper 5er Super Slide bunkhouse(about 10k lbs. )
 
A good universal spec for compressor wheel clearance: Remove inlet boot. Side Play; Wiggle extended shaft tip side to side. IT WILL HAVE SOME PLAY, as the shaft rides on a cushion of oil and not the bearings (bushings) themselves. If it doesn't hit the housing, it's in spec. End play; Pull out and push in on the shaft. Make sure you go straight in and out for proper feel. It should not move at all. Any end play is the sign of a bad thrust, and the carbon rings (oil seals) will be SOON to follow. BTW, most of the Dodge turbo failures were associated with bad aftercooler leaks, not a bad turbo itself... T
 
chad, I posted my turbo blade condition about 4 weeks ago and no one had seen a problem. I saw the pictures of sig's turbo and it looked like a small dog went thru it! I am taking mine to DC today with copies of these posts and demanding a new turbo. Chris
 
Sounds good. I hope I didnt confuse anyone about the Mexico thing. It doesnt matter where the trucks were made. The turbo supplier to Cummins is what we are questioning. Heck it might be a part that Holset is buying from someplace in Mexico causing the problem. I hate to blab and not know for sure, but all I remember is Mexico and Holset being mentioned.

I just want everyone made aware that there is proof a problem in the field, and if not fixed it could be bad news.
 
Are there any lot numbers or serial numbering lists to help out on this?

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White 2001 QuadCab 2500, HO 6-speed, 3. 54 limited slip, Mopar exhaust brake, towing/camper options, DUAL AIR BAGS !!
 
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