Well I've had my '01 super duty for 4 years, it had 266k on it then and now has 297k. The only things that's gone wrong were a power steering line I replaced the night it came home and the oil cooler o-rings not long after that. She's mostly stock, just 4in down pipe, muffler delete, 6637 air filter, and an edge extreme tuner set on 'race'. It doesn't have excessive blow-by, does not push the cap off the oil fill when placed upside down.

Last Saturday while merging onto a highway at WOT I heard a pop and the turbo suddenly got louder. I immediately pulled over and shut the truck down thinking I blew a boot off. I checked all the connections and didn't see anything loose or torn so I continued home. While sitting at a stop light I heard a metal on metal screech which I again pulled over to inspect and couldn't find anything obvious. I left it alone until yesterday for a late night wal*mart run. My wife confirmed I wasn't crazy and the turbo is louder and seems to be getting worse. The boost hasn't dropped any. I had a co-worker come look at it with me and we pulled the intake off and the compressor wheel is chipped on a few teeth and the remaining are mostly bent. Spinning the wheel made the metal on metal screeching similar to what I heard at the stop light. While we were at it I mentioned how the fuel filter bowl is dark and I think it's time for injector o-rings. I'm also thinking it may be time for the injectors themselves to be replaced since it seems to be skipping on cold starts and idling rough lately. The EGT's do climb but I never let it get above 1100 degrees.

The turbo doesn't have any end-play so I think I can get away with a housing and compressor wheel. I think it may be a good idea to replace the intercooler if the chipped teeth are in there. While I have the turbo off it would be a good time to replace the injectors, glow plugs, glow plug relay, and the up-pipes since they look to be leaking.

I was hoping someone could offer some good pointers on what I should do with all these parts needing attention. I would like to upgrade the turbo, injectors, and intercooler. I also want to put some attention on lowering the EGT's. I was going to use this years tax return to pay something off but I would much rather have my truck up and running, especially if i can upgrade it some.

 

Are you wanting more power than you currently have? If so, upgrading to a stage 1 160cc injector and custom tunes may be a good idea for you. At 297k, you original injectors definitely have some wear. Normally, injectors will get to around 200k with good maintenance before you start to see wear issues. This is not always the case, but it is a good general guide to go by.

Do you know what went through your turbo to cause the chipped teeth and housing contact? It there oil in the exhaust housing? You may be looking at a full rebuild. If this is the case, you may want to upgrade the turbo too. The GTP38R is a good upgrade.

I would not worry about upgrading the intercooler. You can wash it out with soap and water if you are worried about something being in there. Odds are, if something ever went in there, it has already passed through.

We can get you setup with these parts I have recommended if you are interested.

 

I'm kind of leaning towards it needing a rebuild anyway. There is is a reputable machine shop here that will build the long block with head studs and metal head gasket for $3700. Past that I would still need the turbo, injectors, up pipes, glow plugs, and relay. My tax return won't cover everything so I'm not sure how this is all going to pan out.

The factory airbox clips were broken and it sucked the drop in filter into the intake tube. I replaced the air box with the 6637 when I bought the truck.