So I removed the turbo again tonight and the back side of the high end turbo was soaked in oil so I'm thinking that is the problem after speaking with a turbo shop they were thinking the return was plugged so removed them and check them as well and nothing plugged. They also said that if a seal was gone that the truck would smoke and maybe a few drops of oil but I have stream of oil coming out about a litre every 20 min . After cleaning the turbos again and checking that all seals were seated proper I reinstalled and no change still pouring out now they are coming out again tomorrow and going to a local turbo shop we will see what this bill will be.

 

Did you check for the drain back hole that was illustrated in the photos i posted some turbos are configured different but the concept is the same, if that hole is plugged the oil can't drain back and will pressurize the exhaust side of the cartridge and also cause a leak. The black soot in the other photo is not carbon, it is oil that has been baked on the inside of the exhaust side of the cartridge where the oil flows. As it gets baked over time when you don't allow the turbo to cool before shut down, it can plug the drain back. Usually have to scrap it out then dip it in solvent to get anything you might have missed.

Either way i hope it works out and you get it fixed. FYI, in the future you can purchase a reman turbo cartridge with impellers for a 6.4 for around 390-450.00 each.

Here is n example

Rotomaster New High Pressure Turbo Cartridge Assembly 08-10 6.4L Ford Powerstroke

I would ask for a quote before you cut them loose on the repair, localy they charge 1,000-1,500.00 for a turbo rebuild. Hopefully they take care of you and only address the issue and not charge another rebuild.