A Neighbor wants me to pull and rebuild her turbo from a 95 f250. I have a good amount of wrenching in the past mainly on 4 cylinders (4g63) and have rebuilt many turbos for those cars and a few diesel turbos, so I'm not going in to this completely blind but I have never worked on these trucks before.

My main question is is it common to run in to bolts that will require extensive heat or other non traditional tools to remove it? Or worse break off? I have read some of them are hard to get to and you need a lot a patience but I want to make sure I can do this job with semi basic hand tools and not get in to a situation where the turbo is half off and the woman is with out a working truck.

Thanks in advance for the help!

 

Patience is the main thing. That and making sure you have a 1/4 inch drive swivel socket set, or at least a 1/4 inch swivel and short sockets, with other extensions, adapters, and knuckles for that frickin pedestal bolt by the ebpv.

 

Follow this step by step and you be fine

TikiWiki : Turbo removal 1994.5-1997 PowerStrokes

 

How To: Rebuild Your Own Turbo - Diesel Power Magazine

 

You don't indicate which part of the country you are in, but if you are in or close to the rust belt and the turbo has never been off, you are in for a very long day.
Make sure to have multiples of every tool listed above as we often break all of them several times during a turbo removal.

If you are fortunate enough to live in the South or the West, then it might not too bad of a job.

 

I would also start spraying the crap out of all of the bolts with a good penetrating oil... You will be happy you did no matter what. You will absolutely need a set of swivel socket to get to the bottom two collector bolts and 1/4 swivel an 10mm with a 3" extension to get to the two rear pedestal bolts.

I will also note the housing bolts on the turbo itself are 8mm 12 point heads. Make sure you have one of those sitting around if you plan on rebuilding it.

Its really not that bad of a job, your chest gets bruised for laying on top of the block for a long time with very limited space against the firewall to wrench... I hope she is making this up to you!

 

I got to like step 8 or something. Freaking stripped the last/bottom back bolt to the EBPV. Anyone any tips or can I just cut the EBPV off and get a new pedistal? I'm all for Performance upgrades WHENEVER possible lol