Cracked turbine housing

[CaptPhil]

So I bought nicks truck a few weeks ago, drove it home from nc to de. Didn't go wide open with it because the cp3 controller wasn't working. After I turned the tune way down I couldn't go close to wide open without hearing this:
Lly rattle: http://youtu.be/EcgnmAtYyck

Pulled the center section of the high pressure s475 and saw that the turbine was hitting the housing and that the housing was cracked. Now i knew the comp wheel was already bad, it ate something, but it isn't hitting the cover. Shaft is straight and tight, zero in out play. Turbine is fine, just shaved a little.

Could a banged up comp side make the turbine wobble into the housing under high load? What could make the housing crack like that?

 

[Muff]

My buddy cracked a turbine housing because the exhaust piping was mounted to rigid and didnt allow any flex when the motor torqued.

 

[CaptPhil]

That's definitely not the case, the downpipe has a big bellow in it before the Atmos.

 

[PureHybrid]

Heat. See it all the time. I wouldn't think the low pressure would get hot enough though, unless its been heat soaked from shutting it down too soon.

I watched the video, sounds like turbo flutter or a slight rapid surge. Most likely a side affect of the issues you found.

 

[MarkBroviak]

The cracked housing is normal since it is cast grey iron but the turbine hit because it was a machined 83mm to 87mm conversion and was alittle tight. The load of drive and boost caused to to touchdown when it was suddenly changed. You can go in there with a fly and some 80grit paper and clean it up and have the turbo rebuilt since the wheels are damaged.

 

[dmax711]

The cracked housing is normal since it is cast grey iron but the turbine hit because it was a machined 83mm to 87mm conversion and was alittle tight. The load of drive and boost caused to to touchdown when it was suddenly changed. You can go in there with a fly and some 80grit paper and clean it up and have the turbo rebuilt since the wheels are damaged.

So this is a common occurrence ? I already bought a new wheel for Phillip what are the chances you have a housing kicking around?:hug:

 

[MarkBroviak]

Yes, I see it quite a bit but it is ok. The turbo is more efficient at lower cfm's if it is kept tight, if you open up the clearances then it moves the turbos power to the right on a dyno chart making it slower to spool up. Just needs cleaned up. I do keep the housing in stock normally or you can send the turbo to me and I will go through for you and fix it and install your new one that you already purchased.

 

[CaptPhil]

Update on this. New comp wheel installed, flappered out the housing for the turbine side (three times now) which didn't fix the problem. I eventually pulled all the turbos and they all look fine, doesn't appear to be rubbing anywhere, but it still makes this sound anywhere close to wot. New housing just came in, of course I am back overseas but not holding out much hope that this will fix it. I pulled the wastegate and plugged both ends to see if it was gate chatter, that didn't work either. So now I am down to thinking that it could be a drive pressure leak between the 475 and the downpipe since the downpipe flange is bigger than the turbine outlet. I have no idea. Glad to get away from it though, am about to set the truck on fire.

To top it off the truck won't hold rail even on a baby tune, 1400uS. With dual fuelers that shouldn't be an issue unless there is a supply problem, so thinking lift pump is no good, which it shouldn't be considering it is basically new. If I try and go wot it drains rail, then pulls pulse, rail goes back up fast, pulse goes back up, etc, so it surges bad. Gonna try swapping pumps between trucks to see if that fixes it. I am pretty bummed so far.

 

[CaptPhil]

Another update and looking for advice.

I put a new turbo in the valley, a 472/87/.90. It definitely spools faster. still making that Damn sound. I really don't know what it could be. It definitely sounds like something rubbing.

The truck has a whine at idle, very noticeable when cold, I thought it might have been the turbo, but now leaning toward the water pump. The pump isn't old at all, but I have read a lot about them whining.

Put two new fpr's in since I couldn't verify the age or condition of the old ones, plus one was from an ii 85% pump, still surging bad close to wide open. Could that be a tuning issue? Can't even go wide open in it. Have an email in with kory about it.

 

[bluessmax]

Another update and looking for advice.

I put a new turbo in the valley, a 472/87/.90. It definitely spools faster. still making that Damn sound. I really don't know what it could be. It definitely sounds like something rubbing.

The truck has a whine at idle, very noticeable when cold, I thought it might have been the turbo, but now leaning toward the water pump. The pump isn't old at all, but I have read a lot about them whining.

Put two new fpr's in since I couldn't verify the age or condition of the old ones, plus one was from an ii 85% pump, still surging bad close to wide open. Could that be a tuning issue? Can't even go wide open in it. Have an email in with kory about it.

Very possible... Shoot me a log and we'll see if mA is going wild!


Sent from my iPhone using Tapatalk

 

[CaptPhil]

I got the tune you sent, I will try it out today.

 

[CaptPhil]

OK, new turbo in the valley, the Amos looked fine last time I had it apart. Still making this sound. Up pipe leak? Surge from the gate opening?
Watch "Duramax rubbing sound" on YouTube
Duramax rubbing sound: http://youtu.be/7ziLYvnUSK4

 

[skintback]

I would say a leak of some kind

 

[S Phinney]

Leak from exhaust side. Sounds much like a blown up pipe gasket. Those things are a must for take apart inspections. People are under the assumption that you will see those leaks easily because of soot. That us not true.

 

[CaptPhil]

Well this kind of Sucks. Finally getting the tunes sorted, this truck is ridiculous. Tune 2 has no traction at 60 mph. Limped the trans today. Rolled into it, blew the tires off, hit a bump, limp. Guess George is getting a call sooner than I had hoped.
Duramax limp: http://youtu.be/885SMsav8XM

 

[S Phinney]

So the truck runs a little more like it should now? What did you find to be the problem?

 

[03badmaxxx]

Well this kind of Sucks. Finally getting the tunes sorted, this truck is ridiculous. Tune 2 has no traction at 60 mph. Limped the trans today. Rolled into it, blew the tires off, hit a bump, limp. Guess George is getting a call sooner than I had hoped.
Duramax limp: http://youtu.be/885SMsav8XM

Honestly that transmission was just built with the best parts possible. I would find out who put it together and give them a call

 

[CaptPhil]

Codes it threw. The turbo codes are just because they were missed during the tune build.

I knew the tc had a problem, it would lock in normal drive in second when it was cold. Tcc solenoid duty cycle would show 0%. Which can only mean that the converter flow valve has a problem. I even pulled this tcm and put it in my other truck and it shifted perfectly. George will get the trans and build it again.

I owe onebadmaxx and Mr Phinney big time, they have been very helpful in getting the problems figured out.

 

[S Phinney]

What gears do you have now?

 

[CaptPhil]

3.73 based on rpm and speed.