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I recently had a hypermax combination pyrometer and boost gauge installed in my 97 PSD. The boost gauge needle flutters rapidly between 10 and 15 when I accelerate hard. The line that runs to the boost gauge tee's off of the rubber hose that goes to the map sensor. Any ideas why the gauge fluctuates so much?
Is the fluctuation accompanied by a pulsing sound coming from your intake? If so I suspect compressor stall. But from what I have been able to gather through reading lots of posts here you have the good compressor wheel. So I don't know for sure here.
I HIGHLY recommend doing that. I just did it to mine and the new sound is well worth the expense. All traces of intake chuffa chuffa chuffa sound are gone and replaced with a making semi truck turbo whine. And the exhaust flutter is greatly reduced too somehow.
My trailer will kill my turbo if I don't do it. Mine is about 10,500lbs and climbing hills the turbo chug is much more of a concern than temps. I gotta lift to get the noise to go away.
You could end up with a whole evening's worth of reading if you did a search on it. Long story short: 99.5-2003 7.3 liter PSD Ford's were equipped with a type of turbo intake wheel that is very inefficient at certain times. They make a stacatto chuffing noise when pulling heavy loads uphill full throttle at around 2000 rpm. The cure is to install the "Wicked Wheel" which is basically the same turbo compressor wheel as the earlier PSD engines had.
I would closely inspect your impeller for any bends or breaks in the veins. It sounds as if the impeller has an imperfection to it. Because your stock impeller on that year should not stutter. Remove the intake boot right next to the turbo and take a looky.
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