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Ill start, mine was dusted i had a hole in my intake that caused it to suck in dirt and such. I have pictures to prove the dusting, my motor is next so go till she blows is my new motto.
My turbo had 160,000 miles on it and the only reason I replaced it was becuase it had a little too much play in the bearing. With those miles on it the blade was in perfect condition. I switched to the 6637 at 130,000 miles. I ran no mods up to the turbo swap at 160,000 miles.
Mine failed at 160K. This was after converting it to basically a van turbo with the 1.15 exhaust housing, and I added an ATS compressor housing at the same time. One thing is for sure, it wasn't dusted or having any surge. Mine failed due to excessive wear on the thurst bearing and washer.
I don't know how the turbo was treated for the first 100K, but the last 60K of it, I wasn't easy on it. Around town, I'm hard on the throttle - I just like to get moving quickly. I would say that a good 30K of the miles I put on it was towing a trailer around 5K, mostly on interstate.
The dealership replaced the first one at 55K for a siezed EBV and a oil leak.
The truck is now getting a second one replaced for the same leak at 89K, and the bearings are shot, too much shaft play, and the WW has been wearing away on the inside of the compressor housing. Ouch.
A new Spearco retro intercooler and Turbonetics unit are sitting here waiting...
I wish my dealer would throw on a free turbo for a siezed EBPV and an oil leak. (probably the pedestal o-rings). I guess the lack of knowledge in that shop actually benefits you. Let'em keep throwin on the new turbos. Dont let them know that the seized EBPV and the oil leak can be fixed without a turbo swap.
Bearing failures, other than the vortex theory(add links if people want to see them), what else can cause them? Off balance turbo i know could cause it but what else?
Boost levels were upwards of 40psi on the stock 20psi rated turbinator. Shaft gave out and the comp wheel ground the comp housing real good. Exhaust wheel was missin some fins. All good stuff, lol