What to do with my truck - blew it up, rebuilding...

[Pirate4x4]

I blew up the turbo in my '03 SO. I was running a TST, 4" exhaust, and afe. I was towing 10,000lbs (two competition rock buggies) when the turbo barfed it's guts into the motor.



DC denied my warranty, because they believed there was an aftermarket box on the truck due to engine codes in the PCM. After lots of phone calls, meetings with attorneys, and being hung up on by the area rep (a real tool, I might add) the only way to get anything done would have been to sue them. I decided to suck it up and fix it myself... I sure wasn't going to pay the $13,000 the dealer wanted to fix it! :--)



I got the truck home, and have it apart. The only visible damage is the fragged turbo, a contaminated intercooler, and bent valves. There are turbo chunks sitting on top of the #6 piston, but no visible damage to the cylinder(s) or piston(s). The head is at the machine shop being checked for other damage...



Questions:



1) Is there a way to o-ring this head?

2) What is the max boost this head/gasket can handle without being o-ringed, reliably?

3) What is the best single turbo for 400-500hp? I need it to be RELIABLE, as we tow fairly large loads across country often. Where can I get said turbo?

4) Where is a good source for intercoolers? Are there any better aftermarket intercoolers I should be looking at?

5) Are there any good aftermarket cams for this motor that make good reliable power?

 

[geusterman]

Contact www.piersdiesel.com in BC and all your questions will be answered. George

 

[Bertram65]

What did you have the TST set on when it blew?

 

[Pirate4x4]

Originally posted by Bertram65

What did you have the TST set on when it blew?

7/7

 

[Vaughn MacKenzie]

The TST has eaten up a lot of turbos, even some to be considered fairly indestructible. The stocker doesn't stand much of a chance. Sorry to hear of your problems Pirate, but more than likely the failure wasn't the result of a faulty turbo and D/C shouldn't be obligated to foot the repair bill.



Vaughn

 

[Vaughn MacKenzie]

7/7 while towing? The stockers have blown on Level 5 before without towing

 

[RobbieH]

Vaughn, on their forum there has been a very lengthy discussion, and let's just say that he realizes that and that's why he's taking care of the problem himself.

 

[Pirate4x4]

Originally posted by Vaughn MacKenzie

The TST has eaten up a lot of turbos, even some to be considered fairly indestructible. The stocker doesn't stand much of a chance. Sorry to hear of your problems Pirate, but more than likely the failure wasn't the result of a faulty turbo and D/C shouldn't be obligated to foot the repair bill.



Vaughn

I don't think I asked for your opinion as to whether DC should fix my truck, or not. I asked how to properly fix it.

 

[Vaughn MacKenzie]

Ah OK, thanks for the heads-up Robbie, and sorry to rehash what you've already been told Pirate, didn't mean to preach at ya



Good luck with everything. I would do like Guesterman suggested and give Piers a call, he will get you steered the right direction. To answer some of your questions best I can:



ć Yes you can O-ring either the block, head or both

ć Max boost reliable without O-ringing is about 40-45lbs boost

ć Best turbo IMO is Piers PDR40 or DD's Jammer

ć I think Piers is working on a Cam for the 3rd Gen trucks but nothing out yet that I know of. DD also has cams.

ć Intercooler. . . you should be able to clean up the one you have and reuse it. As far as I know the only intercooler reasonably available is a stock replacement although the one for the 600 Cummins is probably bigger.





EDIT: Sorry for the funny characters, bullets are not working right on TDR today for some reason











Vaughn

 

[Bertram65]

I would check with Banks for a replacement intercooler, they show one in the latest add in the TDR mag. I bet it is cheaper than the factory one.

 

[DLeno]

Vaughn -- your confidence in both the PDR 40 and the Jammer is higher than the B1?

 

[klenger]

After lots of phone calls, meetings with attorneys, and being hung up on by the area rep (a real tool, I might add) the only way to get anything done would have been to sue them.

I may catch some heat for saying this, but ... does anyone really think that Dodge should pay for this?



#ad

 

[Jumbo Jet]

There's an old saying, "It never hurts to ask". I think he asked.



As far as Klenger's question - No, Heck No!

 

[bgilbert]

I may catch some heat for saying this, but ... does anyone really think that Dodge should pay for this?

Klenger obviously didnt read the entire thread. Looks to me he's trying to fix it himself, he's already realized that he is his own warranty station. Bill

 

[Matt400]

Originally posted by Vaughn MacKenzie

á Intercooler. . . you should be able to clean up the one you have and reuse it.

I have never seen a cross section cut of an intercooler but if turbo chunks went through it I think it would be cheap insurance to get a new one if by chance a piece lodged in the old one comes loose and re-wipes the new motor.

 

[ThomasLawrence]

Vaughn -- your confidence in both the PDR 40 and the Jammer is higher than the B1?

I wouldn't (and won't) run a non-wastegated turbo with a TST box.



-Tom

 

[klenger]

I did read and understand the whole thread before I posted. 'nuf said.



Pirate4x4: I sincerly hope that you can get it fixed with as little expense as possible. There certainly is plenty of knowledge here to help out.

 

[Bob Wagner]

Originally posted by ThomasLawrence

I wouldn't (and won't) run a non-wastegated turbo with a TST box.



-Tom

both 40's are are undersized for the tst box

 

[Walcott]

I can totally relate

It was a blessing in disguise,I was able to put on a kwik-spool b-1,the best part is they now are waste gated!Ran the rollers and raced at Maymaddness,I was worried about lag,all i have for fuel is a ezee box. I have no lag and it much better stock turbo!!!



Alan in AZ

 

[Big_Daddy_T]

Theres a jammer on ebay right now. Might get a good deal.