Please help!

My father has a 2002 PSD 7.3L with a Turbotonic turbo, banks power elbow, DB tuner 6 position tuner, AEM Intake system, Banks Intercooler, and full exhaust.

It's broke...

The truck idles ok and runs ok but it had little to no power.

Takes a while to build boost and it pours black smoke when more than 1/2 throttle.

Searching on this site (impressive!) I got a list going of things to check
Things to check:

• make pressure tester and look for leaks in boots or intercooler
• turbo waste gate
• MAP Sensor – Test with Scan tool
o unplug and drive with it to see an changes
• exhaust pressure sensor

Thanks for the help!

 

Did he blow a boot? Could be a blown boot or even a badly cracked boot letting all boost pressure escape.

 

Did it just start doing this, or has it been a while?

 

For awhile. I replaced a blown brake line and master then took for a drive and noticed the issue. He said "oh yeah, it's messed up. Forgot to mention."

 

Thanks for the suggestion. Gonna try the leak test. Might just replace them. They are about 10 years old and I only did the ccv mod in the fall so they had a lot of oil

 

Slow down on the throwing money part, you may need that in reserve for later.

So... you get to half-throttle just fine, but over half throttle the coal rolls. Uh... you also said you had a DP tuner (assuming a typo).

• You mentioned "unplug and drive with it to see an changes", are you referring to the chip or the wastegate control line (red line)?
• What is your boost when the coal is rolling? Injector Control Pressure? Injector Pressure Regulator signal?
• Did it start doing this about the time he got the chip? Pull the chip (keys in pocket) and do a WOT test.

 

i would check the boots first. that is easy enough to do and you will know if one is bad. it will either be ripped, blown off, or you will see a clean area on the pipes where the air blew the pipes clean from a bad or loose clamp. i have lost the outlet from turbo to intercooler boot twice, and the driver side intercooler boot behind the battery box twice.
one time split, and one time blowing by from bad clamps on each one.
after the second round, i put all new clamps and boots on the truck.

 

Thanks for the help

i get to half throttle fine in regards to black smoke but it is way under powered. The boost gauge is broken and that is on my list of things to fix first.

I was referring to unplugging the MAP as i read in other threads. I did this and there was no change.

It is a DP tuner, thanks for pointing that out. I wasn't sure on the name.

"]What is your boost when the coal is rolling? Injector Control Pressure? Injector Pressure Regulator signal?" no idea. Need to hook up either my auto ingenuity (PITA running it on MAC) or my handheld and see whats going on.

He had the chip and everything was great for a few years. I think the lost of power could have happened anywhere from 1 - 12 months! (the old man never wants to "bother" me when the truck breaks)

 

This is the plan for tomorrow morning. Thanks for your input.

looks like people test at 15-20PSI. I will report back on what I find

FYI the truck has no CEL or anything.

 

Happy Father's day to all the fathers on the board

1st update:

I was busy putting in a new condensor at my parents house so they now have AC but did eventually get some time to mess with the truck.

I made a boost leak tester with a 3" PVC cap and a valve stem.

One intercooler boot is leaking
the boost gauge sending unit was leaking because the line was disconnected. Going to replace the whole line and move the gauge sender.
Then there was a HUGE leak from the turbo outlet into the big "X" thing that all the air goes through. No idea how to fix. It lined up perfectly and the clamp was tight. I am going to take it all apart and inspect.

Can anyone tell me what that part is called that the turbo outlet connects to?
Also, is there a common fix for this?

Thank you for all the help!

Edit: Searching on this site i found a picture. It looks like there is an O-Ring. That may have been blown.

 

There is an o ring at the turbo outlet.

Possible that is your problem.

 

my 02 has an o-ring on the turbo to spyder outlet.

 

So apparently some dummy forgot to install the O-ring last time....



now i got to try and find the size.

Here is the plan of attack

1. Remove IAH (Think that is the name) and install delete
2. Install new Oring on turbo (Napa?)
3. Clean all boots
4. Remove intercooler and clean out all the oil
5. Check turbo

going to search on the site on how to inspect the turbo

 

i got the o-ring and clamp from the ford dealer, if i remember correctly it was less than $10 for both last september.

 

Thanks for the help. Will call napa first because they are closer then a dealer.
going to xtreme in the morning to pick up some small parts.

looked at the turbo. all seems good. defiantly has a small leak in the up pipes but i am going to do that another day. That looks like a real PITA.

TJC transport, i think we may live very close based on your location