I read 3 page's on this post,how about an intercooler full of oil???,it happen's,picture's of this @ www.forddoctorsdts.com/ remember the engine blowby does go into the intercooler and collect's there in the bottom slowing/blocking the flow of air.

 

Don't mean to sound simple but have you replaced your fuel filter? Also on turbos are you not supposed to check end play, as even a new one will have a little up and down? I would also check the charge tubes from the ex manifolds to the turbo, I had a leaky one and I did notice power loss.

 

I am really tossed what to do. Do you think my truck will perform better with a 99.5 turbo on and what is with the big wheel kit for the turbos. You can put on a bigger performance wheel on does that add boost. And also what will my boost psi be at on a 99.5 earlier turbo vs mine?

 

You will lose boost with a bigger turbo if nothing else is changed.
Unless the blades in your current turbo are so worn out that it's lost all it's efficiency.

 

i just up graded my turbo to a stock 99.5 turbo and added the wicked wheel..there wasnt much power gains but did run cooler EGT's...your best power gain will be when doing the HPOP and then again when adding a set of good injectors...

 

what is the hpop

 

High pressure oil pump.

 

I FOUND THE LEAK.....S. Alright i pressured up the system from where the turbo sucks in air. Gave it 30 psi. I have numerous leaks, but will they make a 10 psi difference???? i dont know. It is leaking from the pieces, i dont know what they are called, at the bottom of the y pipe then it goes to the manifold, the square piece that goes to the manifold i guess you could call it the y pipe header. Where the engine gets the air. It is leaking from both sides all the way around those adapters. Looks like a big job, and another thing, it was leaking air out of the valve cover, it was going through the engine and coming out the vent that connects to the air filter tube. Is that normal????. Also i looked at my downpipes from my exhaust manifolds to the turbos and all 4 of them are leaking??? there is black soot at all 4 connection points from the exhaust manifold to the turbo on both sides. With all that said, do you think i could be losing all that boost from all of those problems??? are the leaks on the intake manifold commom?? how many hours to fix both of them. And the leaks on all the donuts on the exhaust, are they common, how many man hours??? Could all that affect my boost?

 

you mean plenums like in this pic??? is it leaking around the boots? or where they bolt down to the motor?? it dont take much of a leak to loose 10 psi

 

Yeah its leaking where it bolts to the motor

 

First thing is repair those up pipe leaks. The leak in the valve covers may be through the valves but I wouldn't worry about an open valve at this point. You could turn the engine over a bit with a socket and breaker bar and listen for a change in the leak. If the plenums are leaking still, that needs repairing. As for man hours, it won't go quick especially if you run into rusty bolts. It depends on your ability.

Both the manifold/plenum leaks will definately prevent you from making proper boost.

 

You can have that Y-pipe off in 30min or less. Clean up the boots, those are the rubberish silcone hoses that connect said Y-pipe to the intake manifolds. that will help them seal better when you re-assemble everything. While you've got the Y-pipe off, read on....

This is a bigger job. You'll be pulling the turbo or the tranny. Most of us have gone in from the top. Kris (Strokin 7.3) and myself are just two of them. Kwik can have the 6-speed manual tranny out of his 550 out faster, so he want in from underneath.

I went slowly, cleaned up alot of other things, swapped in a new turbo with the pipes, and it was an all day job in 95F heat at 8000+ft elevation. (Brutal sun rays). A 10mm stubby wrench is nesessary IMHO, a racheting one would be even more help. You want the updated BELLOWED pipes that International supplies. The are easily available. I went with the ceramic coated ones that Black Widow Diesel offers in a pkg with a new turbo and CAC. You've got a heap of options....

Yes, all can have a negative effect on boost.

I agree with Tenn. Those up-pipe leaks need the most attention. You'll get some mileage back AND a bit more boost. You'll have all the parts mentioned off the truck anyway to do the pipes, so why not do it all while you're in there, again IMHO.

Hope this helps. I'm so stoked. Finally something I have good experience on and can help others out...

-Kevin

 

you will have most every thing off on top by the sounds..(like in the pic i posted) them plenums are just bolted down with ATV..if yours is rusted out and leaking through the rust let me know..if any thing is broke..let me know..I have every thing for the early 99 sitting on the shelf...(every thing that's in my pics in exploded view)how ever the turbo is not rebuild able..it has a 1/8 inch of in and out play...but every thing else is good..you are looking a good solid days work there...so pick a good day....if the EBPV is leaking on the Pedestal get a new rebuild kit from Bob at diesel site..you need 2 sets of turbo O-rings 2 donut gaskets and when I did my up pipes I went to ford and got the right bolts to do all of the up pipes..and new boots I'm sure..when all said and done your low boost should be gone..good luck..

 

Thanks again for everybodys help so far on this topic. everybody here is awesome. I did the full ripdown tonight and i just got in the house and it is 4:17 AM. HOLY **** that sucked bigtime. You have no idea, i would not wish that upon anybody. I started out and everything was cool, got the y pipe out, the down tubes, the boots, then on to the turbo. Had to cut the down tubes out with a sawz-all with a wood blade, did not have a metal one handy. The bolts holding the downtubes on to the exhaust manifolds were too rusted to move. So i did that and moved up top to the turbo i pryed off the exhaust inlet and out clamps with a sledge hammer and a screwdriver, did the two bolts on the turbo on the pedestal, unclipped the exhaust output butterfly valve, dont know what it is called, and moved on. Ripped the turbo out of the back of that engine like it was on fire. The uppipe joints were so bad that on that header,on the back of the turbo where it goes 2 uppipes to one the 2 joints slipped out like there was nothing holding them in at all. They were screwed. Then moved on to the plentum intake pieces got the bolts out and took them out. Sweet its all out and time to party. Not really..... So i went to the bench and started taking apart the turbo. I got the front cover part off and then took the back piece off. After that i took the front wheel off the turbo. Now i just need some parts.
Here are my important questions.

1. There is no in and out play on the turbo, a little up and down, is that okay?
2. On the plentums can i buy gaskets for them because there was none when i took them off, just silicone and i think gaskets would be better.
3. What are bellowed pipes and should i get them instead of stock, and do the up pipes come with donuts and the clamps or do i have to buy them.
4. Should i have the turbo looked at by a professional before i put it in, i kind of feel it is still okay?
5 On the turbo on the exhaust outlet can i remove the butterfly valve or should i just leave it in?
6. What are some good mods that i can do to a stock turbo to make it perform better, if i can use it, i was thinking for sure putting a wicked wheel?

Thanks so much for the help so far.

 

question

1-a little up and down is ok when turbo is out..that will be filled when back on truck and the baron is full of oil..if there is play when in the truck then you have a problem.

2- there is no gasket...go to dealer and get some ford ATV sealant for valve cover and oil pans..

3-I am pretty sure you can not get bellows for the early 99..call IH dealer and ask..but I am sure they do not have them..one of the down falls of an early 99 turbo.

4-it wouldn't hurt to have it rebuilt. depending on miles..you can get a rebuild kit and do it your self as well..but if the wheel looked clean and no play you could just put it back in..

5-that would be the EBPV (exhaust back presure valve) there is a mod for this..but you need to do the pedestal as well..in my sig in mod and fixes is that mod

6-like I said there isn't much out there for the early 99..there is no tricks or a good wheel for the early 99 turbo...

I would do the ccv mod too if you already haven't..it will save you from more leaks later down the road...glad you got it apart..good luck..I have down pipes if you need them..also have the babies butt where the up pipes connect to the turbo..