It sounds a lot like a leaking up-pipe from what you describe.

 

I apologize, I have not come up with a video for you guys yet. I tried last night but all the videos I took with my phone, I couldn't hear it on the video. I will try again but I'm first gonna look at the up pipe where it goes into the turbo on the back right(from the front of the truck) of the turbo. I had a hell of a time getting it to line up when putting the truck back together from doing the oil cooler. I was ignorant at the time and forced it together using the v-clamp to draw them together. Apparently that is a no-no. I've been doing a lot of research the past couple of days at work, desk job without oversight gotta love it!, and it really sounds like that is probably the issue. Some additional things I've noticed is a small smell of exhaust in the cab. Didn't mention that before as it was there before the oil cooler upgrade, but gone right after I put it back together, but then reappeared about the time of the noise. Figured it was just normal. Lack of power on takeoff/very slow to spin up the turbo sometimes but not all the time.

What is the best way of getting it to align without disassembling all kinds of crap again. I'm tired of the hood up, it's been up more than the truck has been on the road it seems like! I ran across a video of a guy and a ratchet strap to pull it in. Is that a good idea? I also ran across a video of a guy and a spray can of copper gasket maker. Is that a good idea? Seems like I should probably be loosening up the turbo bracket or the turbo, loosen up the bolts at the other end of the y pipe, and then put it together with the v-clamp and tighten everything back down. What is the minimal that has to come out, degas? FICM? air intake pipe to turbo? I'm also starting to think the bellows might be leaking as I could smell exhaust before doing the oil cooler, could have just been a leak though elsewhere. I poked a light up in there real quick like and didn't see any soot from underneath. Is there a way to tell without pulling it out?

I'm planning on doing this Saturday. I'm also gonna pull all the boots, clean them up put them back in. Also gonna check and make sure all the other v-clamps are tight. I only had a few minutes last night with a flashlight, but I didn't see any soot or anything around any of the v-clamps at all or any signs of leakage at the boots.

 

Well, it didn't take long to figure out this morning. Started poking around with a flashlight and found some soot on the bellows on the passenger side of the y-pipe. Had the wife start the truck, immediately smelled exhaust smoke and could hear it right above me. She stomped on it, smoke everywhere out of it.

Haven't started shopping around too much yet. Are the MBRP's a better alternative to the OEM? Since I have to replace it, I'd rather not go stock unless they've improved the design and this won't happen again. Otherwise, I'd like to get an improved design aftermarket without spending a fortune. Suggestions/recommendations?

 

Looked at it again to double check which pipe, it's actually the up pipe, not the y. Glad I looked again before ordering!