T14 Turbo Repair for @DieselCreek 1964 D8H Cat Dozer – BACK FROM THE DEAD … WILL IT START?

foreign welcome back to area Diesel Service so today episode 2 number one most viewer requested collaboration we're back with diesel Creek so if you're not familiar with diesel Creek please go over there and check out his channel we'll drop you a link below he does some of the best crusty Rusty resurrections and will it runs on YouTube great Channel over there good friends of area Diesel Service we have another project for Matt so in this box is a turbo charger off of a machine that you have probably seen this thing is a 1964 caterpillar d8h bulldozer big boy this is a 46a serial number vintage again 1964 powered by a Caterpillar d342 engine she's rated at 270 horsepower 20.4 liters so we're talking about 1250 cubic inches so somewhere in the vicinity of a 50 000 pound Dozer checking in at 59 years of age that's what it's off of the story as we understand it Matt got hooked up with this machine several months ago the thing had sat for 15 years Matt put out a video we'll drop you a link to that as well they went out went through the standard diesel Creek routine and got this thing back to life when they fired it up the first time somehow they busted the pony motor off of the engine if you've seen the prior videos if you catch it you can hear when he shuts this machine off you can hear this dude grinding to a halt the turbo hitting the housing I don't know about all that oh is that what that noise was nice that's not good never a good symptom when you're describing your turbo as grinding this is suspected to be a Garrett t-14 turbocharger again old school right this thing is no longer supported with exception of us at area Diesel Service you're not going to find service components you're not going to find replacement units this dude is dead as far as that goes we drew the Short Straw send it out to area Diesel Service and see if we can bring it back into life so we're going to open this thing up live with you on camera and we're going to see what I've gotten us into 90 pounds on 270 horsepower of engine today we can accomplish 270 horsepower with 40 pounds of Turbo so a lot has happened in 60 years the turbo industry is no exception this thing is uh fairly Antiquated and for those of you that have been following along Matt always sends us a letter in the description of the situation and this one is there's no exception this one Matt says this one wasn't my fault Matt did not disassemble this and send it to us in pieces like the injection pump we saw last time this thing should be in as removed condition [Music] foreign I can already tell you that the boys in the back are going to be excited about this um initial inspection she's been leaking perfectly aligned with Matt's Channel crusty and Rusty covered in schmoo in need of service this thing has also had years of deferred maintenance if you will we've accepted the challenge if anybody can whip this thing back into shape it's going to be us at area Diesel Service so we're going to make kind of an initial assessment here the turbine housing super pitted right this thing is getting pretty thin you can see some torch marks where he had to go in and cut the studs off the problem is there are no components left so we are basically going to have to work with what we've got we may be able to find some service components but as far as hard Parts it's going to be tough the outlet flange where the exhaust connects to the machine right so this is exhaust in this is up and out the stack busted here mud dauber Nest right par for the course I don't know if you can hear that we'll try and get the mic a Little Closer right so that's the noise that you were hearing when he shut this thing off right the engine came to a halt the turbo kept going not good never want to hear that out of your turbo if you're questioning the quality or the condition of your turbo the crude test is the first thing check radial shaft player the shaft is coming through in this manner we want to go up and down right we're trying to see if the clearance in the journal bearings is excessive shockingly the journal bearings feel pretty tight the second Layman's test is to check the thrust right to the wheel shift this away axially I'm pretty sure the microphone's picking that up as eighth of an inch maybe 3 16. and there is some clearance in the thrust components axially but not enough that you can feel it with your bare hand if there was no clearance the turbo wouldn't turn but it's so precise that you can't feel it with the bare hands thrust is out at least it sure feels like that the uh the shaft is still in one piece the grinding that we're hearing is all on the turbine end we can't tell much the blades at least the x deucer or the outlet of the turbine wheel blades look okay so hopefully it hasn't ingested some of Matt's engine but we really won't know that until we tear it down right that noise on his video right there that's no bueno desperate times call for desperate measures remember when this thing was modern technology I was negative 19 years old we're going to have to call in reinforcements and find somebody around that that knows exactly what we're looking at so we're going to bring in our founder and president Val leafers well I knew you had to have something old when you called me um well the little girl's got a case of acne hadn't she um nothing just out of line I wish I was as good a shape as this is because we're pretty close to the same age anyway you've got uh oh well that's not too hard to diagnose is it some trust wear yep well very very typical of what what you're going to find in here yeah it's uh it's an oldie but goodie it's not like some of them that are just totally deteriorated away I think with some uh tender loving care we might be able to make a serviceable unit out of it but you know what if you look at this exhaust on here and and the size of the engine I think we got a probably a turbo that's halfway of an example but this rasp can do the same job that we're doing with that one yeah it's uh there's been some advancements yeah yep oh that's pretty cool be excited to get that in the back and open it up and see what uh what's going on in there so this is off of a dozer that was built in 64 right we opened in 73. is this something that back in the day was a regular appearance pretty well yeah these were this this has technology that's probably even back farther than that yet but a lot of the technology you see in this one came off of some of the uh turbos that were in World War II uh on airplanes and it's going to have a nozzle ring in it which is held on by these bolts around here and it's a nozzle ring instead of changing the AR the turbine housing you did it with a nozzle ring uh definitely not a verbal geometry at this point because it's a fixed geometry well it's it's a predecessor was I think a 1402 that had a a two-piece bearing housing on it which was bolted together so this is uh this is a real modern update for the original part we started with I want to be kind of excited to open up and just see what we can do with this old girl this is kind of cool because conceptually not that much has changed right he's still got uh exhaust coming in running across a turbine leaving out here and same thing over there right air coming in brought in blowing out yeah it's so you know conceptually um same thing but the amount of engineering and advancements that have gone into wheel design flows and geometries and all that is well you thought that other turbo could do as much or potentially more than this thing and that turbo is it's 20 years old yeah 20. yeah or older whatever yeah considerable so very neat I'll be answer you just go back and get my hands dirty on that one our machine shop can do wonders with this yeah so we don't know what we're going to get into but we may end up manufacturing some components for this um the noise that we're hearing right we said it was axial play but we can tell that when I push the turbine that away it's not the blades contacting the Contour of the housing when I pull it this way not good so we suspect that the back side of the turbine wheel has run up against the back side of the nozzle or the back side of the bearing housing or the heat shield does this have a heat shield yes it does yeah what's that the compressor wheel is going to be ground off because it went that way instead of uh 30 000 spit you're going to have interference fit yeah is this from the Labyrinth seal era right so this thing doesn't is that on the turbine end yeah right so we've talked about it before but the turbine end runs a butt cut piston ring on on Modern turbos this dude is of the era where there isn't a seal they kind of cut a thread and just the direction of the thread is chasing the oil opposite keeps the oil in yeah so it's almost like it's engineered to leak but they cut this thread so the oil comes back where they want it to be and then there's enough oil that burns which for Farms carbon and then that carbon gets around that that particular seal and really makes a pretty good seal on it so this would be out of the box might leak a little but by Design right take it out yeah take it out and load it up and and work it and it'll seal up self-sealing turbo um yeah it's come a long way well I'll let you carry it with me I have no doubts and again can't get the hard parts right so you may see not only the repair of the turbo but you may see the repair of some sub components we'll scrounge and see again we don't even know what we need yet if there's any out there right we can find it we've got those connections but that'll be a challenge we're ready for it we're going to get this thing written up on a work order we'll transfer it back to the turbo Department sometimes those folks are a little camera shy so we might just be given updates throughout the process if we can get them to allow us to capture their work we'll certainly bring you along show you what it's going to take this is going to be a fun one again this is Obsolete and not supported so rebuilding it back to a quality standard is going to take some effort also while we're up here this opportunity came to us as a viewer suggestion collaboration without the help of you guys as the viewers putting these opportunities together we wouldn't be able to bring you this type of content and we appreciate that with that said in other people's videos where it looks like they could potentially use our help tag us in a comment take a screenshot where you did that and email it to us at Parts at areadieselservice.com we'll throw you a hat and a pair of gloves right send us your name and address show us a screenshot of where you shared us or recommended us we'll throw you some swag that's enough of that we're going to get this thing tagged and written up back to the turbo shop we'll bring you along and see what we can do we're back in the turbo shop Val has given this thing the official Judo chop we've got her scattered on the bench and we've made some initial observations okay we've got good news and we've got bad news bad news is it's pretty bad we're going to go through what some of the issues are but the good news is that we're pretty confident we can fix this thing we're going to start on the turbine end and just kind of walk through what we're seeing for some of the issues okay first thing uh the outlet flange connector you can see a couple of bolts this is where the exhaust connects got a split busted right there pretty gnarly so that's going to take some attention overall condition of the turbine housing is crusty she's pitted she's bad limited options here we're going to clean it up and see what we think also Where It Bolts to the exhaust manifold the surfaces are not flat and true gonna take some work there biggest issue is in the surfaces where the rest of these components mate together right so this surface is critical this component fits in there and we had a pretty significant case of rust jacking right this thing started to come apart and rust and it split and it grew and it's gnarly and nasty perfect example of some crusty Rusty for diesel Creek but this is not where you want your trusty Rusty these are critical dimensions so that's whammied we're gonna have to probably do some surfacing here surfacing here we may have to come up with some shims or additional material to make up the difference this is the nozzle that we briefly spoke about at the parts counter it's actually in pretty good condition turbine wheel this is a critical area here this is the journal where the bearings ride it's actually in pretty fair condition and we haven't cleaned it up we haven't taken any measurements we don't have any contact on the turbine wheel to turbine housing fit clean it up do some measuring and inspecting see what we can do with that heat shield doesn't seem to have the same rust jacking issues we looked at earlier bearing housing so when the rust jacking heard and you can still see some of the shims we were looking at earlier you can see here there's a whole there's a I mean there's chunks of it right so this thing grew again we haven't cleaned up and inspected but we suspect that this surface is no longer flat and true gonna take some machine work there uh the journal bearings again need to clean up and be inspected and measured while they're dirty and while we're looking they don't look terrible [Music] all right so the grinding that we were hearing at the parts counter the grinding that you were hearing on Matt's video the thrust play that we discussed is here right so I don't know how well this is showing up but that dude is chewed up as is this thrust component so like we discussed this is what's controlling axial play inside of the turbo this is the Labyrinth seal that we discussed kind of looks like threads on there these components are hammered dunzo there back plate looks all right here's a bag of Struggle Bus right this is the Crusty Rusty bolts that busted and stripped trying to get this pig gutted so we're gonna need a little bit of Hardware no big deal because the thrust was out it allowed the compressor wheel to come up and contact the compressor housing it doesn't look terrible which is fortunate because you couldn't get one of these if you wanted to fortunately the design and the configuration of this Turbo calls for a shim to set the stack up dimensions a shim goes on the back of the wheel that determines the relationship between the compressor wheel and the compressor housings we've lost a little bit of material on this wheel it's going to take some manual labor we're going to clean this thing up balance it take a deeper look at it but we suspect at this point that this wheel can be saved and we're just going to have to compensate for the wearer here by stacking the wheel deeper into the housing again too dirty now to know for certain but we don't think that's going to be a problem component availability likely to be a challenge here we discussed at the counter this thing's no longer supported with exception of what's left at area Diesel Service believe it or not I couldn't believe it we had in stock a new seal insert a new thrust component so those components that were hammered that we looked at so we've got those brand new I'm shocked Journal bearings we had two different sizes of Journal bearings so we talked about the journal on the shaft if this is not acceptable we'll have to machine this undersize and then use a custom bearing right to take up what material we had to remove and then the same thing as possible inside the bore of the bearing housings we don't know what the journal in here looks like yet standard operating procedure is if it's whammied take some out put a horn on it get the surface finished good and then take that up with an oversized bearings we need to clean this and inspect it to really get a game plan if we've got to machine here if we've got to machine here we've got to make sure that we can come up with an appropriately sized bearing fortunately we're going to get to see some of the Machine Shop in action with this thing we're scattered now we've got to clean it up do some measuring do some final inspection and then we'll get a game plan we'll talk about opponents or component availability and or solutions for those issues and we'll bring you back step two complete we'll see in a little bit we're back in the tear down room we've got what's left of Matt's turbo here in the basket we're getting ready to move this thing in throughout the cleaning process this contraption here is a Peterson bake oven and we're going to load this basket into this oven we're going to run this stuff at 600 Degrees we're going to run it for about six hours throughout the course of the night and we're going to cook this stuff down right we're trying to get rid of the schmoo and the grease the oil and carbon we're going to bake this stuff so that when we move it over to the black cabinet we don't room the media so we're going to load this thing up and we'll show you what happens when it comes out [Music] all right we'll show you what it looks like when we're done still a little warm oh oh would you please [Music] all right here she is so again we went 600 Degrees for six hours point being to try and solidify the shmoo and we've done just that so this was all [Music] Grime wet greasy grime and now you can see she's just busting right off of there bearing housing also just turns it to powder crumbles right off that's step one in the cleaning process we're going to take these components we're going to move them over to the blast cabinets that's next we're going to start these with the most abrasive material it is terracotta and quartz mixed together that's going to get us through most of the gnarly stuff that's left on these and then we'll move at least the aluminum stuff over the glass dust and give those a once over baking is done we're going to move it on to the next step in the cleaning process so we'll bring you along foreign so this is the last cabinet side to tear down I know it's kind of a dungeon in here but it's a necessary evil we're tearing down hundreds and thousands of crusty greasy grimy turbochargers and this is where we do it just uh it is what it is it's a dirty process how we've figured out how to accomplish it so we're going to take these components move them into these cabinets and when they come back out we'll give you another look at them and then we'll take it from there to the next step so we'll bring you back I got a phone call from the turbo shop they have some news or findings to report I don't know much other than they weren't very good this is the turbine housing off of mass turbo right so we followed this thing through tore it down disassembled it it is now cleaned up and the inspection has been performed right this thing's pretty gnarly we knew quite a bit when it was still assembled and together from our inspection that it was not in very good shape even when it was dirty and before it was cleaned up we could tell that rusted and pitted to the point where a lot of the original material is just completely gone now that they've cleaned it up we can take a closer look and they already found bad news and it might be hard to pick it up on camera but right here is what we refer to as the tongue so that is almost the direct point of entry where the exhaust gas is first introduced to the turbine wheel it is probably the most highly concentrated area for exhaust temperature or heat and this dude is cracked and right there if the camera is picking it up there's a hairline crack and it goes Plumb through to the other side or the outside of the casting so right here probably hard to see on camera but this dude is you know maybe an eighth of an inch thick it's just so much of the original material is gone away there's not enough meat left for us to do a braised job that's something that we do regularly right just like you've seen on a bomb or Keith Rucker but Grime that dude out we do a TIG braise but it is possible to braise and repair these housings but this dude at this point I'm going to say has reached end of life so there is no serviceable life left in this component which is unfortunate okay we've spoken a couple of times already this thing is no longer supported by the original equipment manufacturer this is a Garrett unit this thing's 60 some odd years old they don't support it anymore the aftermarket supported this unit for many years it's so old that the aftermarket doesn't play with it any longer potentially a devastating blow to the diesel Creek turbo repair I don't know what we're going to do at this point I'm going to go back up to my office that's kind of what I do and see if we can't find another solution if not into the scrap heat she goes and Matt's going to have to find a plan B for his engine so don't know where this is going to go from here but we'll bring you back when we have a plan uh you saw on the last update that we have a turbine housing issue and we've mentioned before that we are class A hoarders this is where the majority of the hoarding happens this is the core storage facility for area diesel at least the cores that aren't going to be required in short order this is the long term storage solutions pretty good behind the scenes you'll see here everything is fairly organized as far as dirty cores and components we're looking for box 54 theoretically box 54 has two of these turbochargers both in graded condition they should be acceptable on the compressor side and the turbine sides we don't know uh when we got them where they come from but they are in the archive there should be two of them in 54 so uh we're in the 100s here over to 70 number one up here 54. so tucked in the corner we're going to pull it down and see what we've got [Music] [Applause] cannot believe it there she sits that is a spitting image of Matt's turbo uh yeah it ain't the prettiest thing but there's uh there's just not any of this stuff out there so the head of the turbine wheel is completely gone this thing might also be a boat anchor um we're running out of options so we're gonna take this Turbo we'll take it back over to the other facility and we'll yank that off and see if it's going to be any good at first glance it looks better but again turbine wheel is completely gone so it likely got into the turbine housing we'll get this thing loaded up and we'll uh bring you back once we get this one torn down we'll check back can't believe it take that back to the other shop see if we can make any good out of it foreign [Music] Plan B on the operating table here these guys have scattered it obviously we have not finished the cleaning process but we're trying to get preliminary inspection completed to see if this is potentially a viable solution for the components we were not able to harvest out of match turbos this turbo when we looked at it we went and picked it up from the courthouse and we could tell that it had experienced catastrophic failure this is what's left of the turbine wheel you guys saw the turbine wheel out of Matt's unit this one had a high speed come apart catastrophic failure and it got into the turbine housing that we're trying to save right in here so this is where the Contour of the turbine Wheel rides looks pretty bad but we think we can work with this okay there are no components out there we can't buy a turbine housing this one even though it looks pretty nasty it's considerably better than the one from Matt's turbo the pitting is it's hard to say that this is good but this pitting is less than the pitting on Matt's turbo the meat where we were talking about the crack being all the way through on his housing there's probably three-eighths of an inch of material left in the tongue area so this thing still looks pretty nasty but it's a far cry from the condition of the one that came off of Matt's turbo also we spoke before about the compressor wheel even though this turbo experienced a catastrophic failure the compressor wheel did not we need to clean this up and do an inspection but it looks like it's probably in better condition than the one from mat Turbo bearing housing don't know we think we can salvage what we've got from max turbo this one potentially is in better condition the surface where the turbine housing meets up with the bearing housing is not nearly as pitted and this one the shim and this one also deteriorated but it still looks to be fairly flat don't know there heat shields both got hammered when the turbine wheel exploded and compressor housing we didn't look at it too deep Max compressor housing is good but this compressor housing looks okay as well that's where we're at for now we're going to run these through the rest of the cleaning process and then we'll get all of the components back together and we'll have an actual game plan for what we're going to do here so we'll bring you back yet again then it could be walk out too far nine it's not going to walk a quarter of an inch or an eighth of an inch anything anyway it's going to be a yeah twenty Thirty thousands to do that and it contacted and made this screw in it here and that's all because the thrust was out of it so if we get to good thrust and we determine that this variant is here won't walk in and out on us then we've got got that licked so you followed us through some of what we're going to call phase one right disassembly cleaning and inspection there's been a few curveballs throughout the process but we now have what we believe to be enough material to go back together with a new turbo for Matt first thing why did it fail right why is it here we heard on his videos this thing was grinding right there that's no bueno we inspected it at the parts counter we found axial play right so we knew the thrust was out now we've got it disassembled cleaned up and we can see what's going on the failure that was presenting the symptom was in the thrust components what we have is classic textbook oil contamination so it looks like somebody threw a handful of gravel in this thing and the oil contamination chewed up the thrust components that's the you know we talked at the counter we had a quarter inch of axial play that's because the contaminated oil wore these components so severely that we developed that amount of end to play along with that are the journal bearings so these are the bearings that ride on the OD of the shaft and in between the ID of the bearing housing theoretically or factually this turbine Wheel rides in a film of pressurized oil so there is no metal to metal wear inside of a turbo but the journal bearings on the OD show significant signs of oil contamination grooving on the OD of the journals surprisingly the ID looks pretty good and this OD of the shaft looks pretty good right so there's centrifugal force on these the contamination would tend to want to to gravitate or go to the towards the OD when it did that it also got into the ID of the bearing housing so it is grooved significantly the surface finish is beyond salvageable use it's going to require some fixings we've got all of the parts scattered up here the three wise men met back in the machine shop and discussed these components and the required repairs and we've got a game plan we're going to kind of Step through each component talk about what's going to happen things are getting ready to get exciting right these components are getting ready to split up and head back to the machine shop so unlike an injection pump which you may have seen us do before injection pump technician takes that one product Cradle to grave they walk it through clean up tear down disassembly inspection rebuilding calibration one person the entire process the turbo world is a bit different we've got folks that are in disassembly we've got folks that are in cleanup we've got folks that do the inspection the machine work the reassembly so this thing splits up and goes through many different paths throughout the remanufacturing or rebuilding or repairing process and it'll come back up to a single Builder and this stuff will all get slapped back together enough rambling we're going to take a look at some of these components specifically turbine housing this is the unit off of the turbocharger that Matt sent us we've already done a review on this thing but again cracked in the tongue too thin to braise the uh rust and corrosion severe this thing is it's done right this can no longer be repaired this is headed for the scrap bin this was the outlet connection off of Matt's turbo charger bolts on here and this is what the exhaust system connects to it's cracked corroded pitted we're going to have to make this we'll get this thing drawn up get it recreated this is the turbine housing off of Plan B it has been baked and blasted we didn't bring you along for the cleanup process but you saw some of the teardown for this unit it's hard to say that this is better but but it really is it's still not what we would like to put out but again guys this thing's 60 or 70 years old you cannot get these components it was a miracle that we had a core on hand this is the better option to get something back out to math that's going to run it's going to need the hardware removed and drilled same thing on the flange where the bearing housing meets up it was a struggle to get this thing apart most of the hardware busted this thing will have to go into the machine shop get the hardware drilled out re-threaded helicoiled possibly a little bit of work there not a big deal the big deal is the the damage so we discussed that the turbine wheel was gone from this core Turbo when it came apart the turbine wheel got in to the bore of the turbine housings it's probably too significant for a buff job a lot of work needs to happen there face it on the inlet same thing with the hardware here and here we'll take you back to the machine shop and let you check out some of that that is the turbine housing so we talked about on the boat anchor housing it's got the big crack all the way through it's in the tongue area where the exhaust temperature is most concentrated we're not real happy about the Carnage on the bore of this thing but this turbo operates with a nozzle okay this is a changeable component that dictates the speed at which the exhaust gas is introduced into the turbine wheel so if you want it to run harder change the nozzle ring to something that's choked up tighter this component is what determines how the exhaust gas meets the turbine wheel so yeah the Contour is bad we're going to have to work on it but in reality where the rubber meets the road is between this component and the turbine Wheels we can fix that that's what we do it's less than desirable I wish we could get a brand new turbine housing but we can't right this is the real world this is what we're going to have to do fix this housing we're fortunate that we had something a little better than what he had to start with this is the turbine wheel from the diesel Creek turbo it actually is in fantastic condition All Things Considered this turbine wheel and mats bearing housing we're of standard specifications so these components had not previously been machined the journals where the journal bearings ride one here and one here are in fantastic condition especially considering the contamination issues that are apparent on some of these components it's currently at standard spec so again has not been machined we are going to polish and see what happens we will likely grind this undersize so not online like a crankshaft right you've seen or heard 1010 on your crank journals same thing we will grind this undersize back to a quality finish and we'll get a custom bearing that makes up the difference this thing also destined for the machine shop they'll do some work on the journals if that doesn't work we actually had in stock a remanufactured turbine wheel this is off the shelf it has previously lived it's good to go for another cycle of life this one has been machined already five thousands under on the journal so if we can't save Matt's wheel which there's no reason to think we can't but if we can't save it we do have a plan B for that again the turbine wheel out of the core that we had it was gone right so we can't save that one bearing housing yeah during the tear down process we talked about the shim that had deteriorated and we talked about the rust jacking right these layers of shims had corroded so significantly that they spread apart and caused some damage those shims cannot be purchased so this stack of shims is something that we farmed out to the Machine Shop North of us they got a Fab shop up there they've got a water jet we drew out what this shim stock looks like and they made us a selection of different thicknesses and different shims when we do the repairs if we've got to remove material from this now pitted and untrue surface we now have the shim stock required to effectively put that material back where we have machined it that was a hurdle um not a big deal we've got a solution the bearing housing so we've got two of them this one was mats this one was out of the donor turbo the journal where the OD of the bearing fits into the bearing housing is scored that's where the foreign object or that's where the oil contamination was most prevalent standard operating procedure is to hone that out go to a larger OD again custom bearing to make up the difference restoring Factory clearance specification this turbocharger Garrett T14 throws a little bit of a curveball in there generally in most turbo configurations this journal bearing is captured by two snap Rings you pop one snap ring in a Groove in the OD of this bearing housing you slide the journal bearing in and you capture it with a snap ring on the outside now it's contained the way that they designed this or built this I don't know if you can see it but there's a step inside of here acting as effectively the inside snap ring it makes it difficult to pass a hone through there because there's a step that is smaller than the surface area where the bearing rides okay a couple of options how do we get that grooving cut out how do we get it to the next nominal bearing size two options we can try and come in with a boring bar and just stay away from the step and hope that we get a good enough finish maybe we can do a Polish on there without knocking the step out second option cut the step completely out and then cut a Groove for a snap ring then take it and hone it and fit the journal bearing as we described second problem again the shim that deteriorated has pitted and warped this surface we've got a good register here that we can pilot from that we can machine from this is known good machined area so we can Chuck here we can do the bearing work and then while we've got it chucked off of this known good register we can face it here and then turn it here so we can bend it around and do the work on the back side variety of options we have not necessarily determined which way that's going to go this stuff's going back to the machine shop and they will be the ones that actually pick the plan of attack but again like we mentioned the three wise men met at the table there's a hundred plus years of experience if those guys can't figure it out and come up with an effective game plan I don't think anybody else could either I'm comfortable and confident this is not going to be an issue if it is the bearing housing out of Plan B was in similar condition we've got a backup plan if needed the other option we have we talked about the Labyrinth seal area so if either of those areas don't meet specification we actually had in stock this is a machine shop repair component for this 60 year old turbo if this area is not satisfactory we'll machine it out press in put a couple Dutchmen in there and restore that area back to factory specification we spoke of the primary mode of failure primary problem with this turbo that was in the thrust components these are hammered Beyond repair it's not really something you generally repair anyway if it's bad you replace it that's normally not a big deal if you can get the parts this thing still blows my mind this was a brand new Garrett authentic thrust insert in stock on the Shelf been obsolete for many many years we still got them and the corresponding thrust component that mates up with it also in stock on the Shelf restoring the factory thrust clearances back in this turbos this I would have thought would have been the most challenging component to acquire and it was on the Shelf so very pleased this is the nozzle ring we spoke about for the turbine housing it's good to go cleaned up just fine heat shields so this was out of Matt's unit you can see a split here we could take this back together grind the weld back off I haven't seen the heat shields out of the plan B core turbo maybe they're in better shape maybe we'll be fixing this uh this one got a little booger there not concerned we can take care of that no problem compressor wheel cold air side fresh air side whatever you want to refer to it as this is where the charge air so fresh air from the filtration system drawn into the turbo and discharged out of here fed into the engine and this is the compressor side we've spoke about this already we know that when the thrust components failed it allowed the compressor wheel to reach out further into the compressor housing and contact the housing housing's got a little bit of minor scuffing no big deal that'll buff out and clean up compressor wheel had a little bit of material removed and again we spoke about the way that this thing goes together this wheel is shimmed to dictate its depth or relationship to the compressor housing we could have theoretically salvaged this wheel we would have just shifted it deeper down into the bore but miraculously even with as catastrophic of a failure as we had from the plan B turbo the compressor wheel was in fantastic conditions absolutely zero contact no foreign object damage nothing on the tip of the compressor wheel this thing's in great shape so we'll finish cleaning this up when we get done it'll look like that one we've got a better compressor wheel to go back together compressor housing it's been cleaned up again we might do a little buff job on the trim on the Contour the bolts all look like they came out good chase them with the tap may have to do a helicoil or or two but the rest of the compressor housing looks pretty good considering what we started with last thing is the back plate not much going on here this is just what connects the compressor housing to the bearing housings very fortunate and thankful to have lucked out and had one of these in core status in The Horde without that this thing probably would have been done so this is what we know as of now as of now because many of your inquiring minds want to know where are we at cost wise and this is the reason why we don't see too many of these turbos anymore because this repair is likely going to exceed the value of Matt's bulldozers as of right now five hours in 125 an hour we've got 625 dollars in labor just to get two turbos torn down cleaned up and inspected we also have at this point the expense of the sublet for the manufacturing or production of the shim stock this was 215 dollars for the material and the water jet labor and then we also have the expense of the plan B core turbo we're assigning a value to that turbocharger of 500 I know that seems crazy but you can't buy them and it's worth something right we kept it we stored it we saved it for a rainy day somebody's gonna need it we had one it's expensive five hundred dollars for a junk turbo it is what it is so 500 six and a quarter we're at 11.25 we had 217 here so we're 13.50 guys and we haven't even got into the machine shop and we don't have a turbo so not trying to run me off but this is an expensive project this is going to end up being extremely expensive and in most scenarios going to cause a trip to the scrap yard with a bulldozer right nobody's going to put a five or six thousand dollar turbocharger onto a five or six thousand dollar bulldozer except Matt at diesel Creek enough rambling if you've stuck around this long things are about to get interesting and exciting these components are headed back to the Machine Shop some of those folks are a little camera shy so you might just get a couple hand models and a narrative explanation maybe we can coax them into giving us some of their input you're going to see some of our equipment which I'm excited to bring to the YouTube world and we're going to move this thing on to the next phase so we're going to bring you along we've made it back to the Machine Shop we've got the first component chucked up here all right we're in the inco this is effectively a Bridgeport clone and what we're after in this step is the hardware so you saw us bust all these studs during the disassembly process we're going to watch the guys go in and fix this thing first thing we're going to do is come down with an End Mill and we're going to mow down the top of that stud so we've got a flat surface will change out to a center drill we'll come in and get us a center in what's left of the stud we'll come back with a drill bit we might take it in one or two bites we'll drill down through the existing stud and then we're going to tap this for a helicoils easy manual machine work these aren't coming out so we're not even going to attempt to extract them we're going to drill them out we're going to heal a coil we're going to set up for new Hardwares all right so again the top edge of that stud is not flat and true and you can't Center a drill bit without a flat surface step one come down with an End Mill and flatten off the top of that stud you can see him there watching trying to establish a flat surface to work from all right he's got her decked off Gonna Change tools we're gonna go to a center drill now if we were trying to extract we'd be super concerned about getting dead center on this but because we're going to a helicoil we're just going to eyeball it making sure he's got her lined up good that's it just get him a center so his drill bit doesn't try to walk on him tool chains again looks like he's going to go two steps on his drill bit picked up the small bit first a little Lube job not gonna get in any hurry here it's gonna Peck away at it again that stud's been in there for 60 years so small bites keeper lubed we don't want to pack a bunch of chips in there and bust a drill bit so there it went drill bit number one complete drill bit number two so this is tap size for the Helicoil he's got a pilot knocked down through it so this one might eat pretty fast so he just poke through with this big bit chained her out looks like he might be getting ready to power tap gonna get exciting yeah Looby Dooby so start it good and centered with the mill gonna drop the knee down I'm gonna hand tap it from here I would assume trying to get it out from under the spindle where he can work on it he's not concerned about staying centered on that hole anymore he's done with the mill at this point got a tap wrench on there gonna do this manually so he can feel what's going on we don't want to run the power tap down in there and bust the tap off never a good day it's like seems to be cutting pretty good all right stud gone drilled out hole tapped let me grab the tool for the Helicoil he's being kind there with his hand and trying to protect us and the camera from the shrapnel and juices but all right it's got a helicoil tool so if you haven't ever seen a gila coil you just go oversized with the hole and then you thread in a new set of threads standard repair for a tapped hole there she took all right so now he's screwing that repair insert down in there you're going to want to make sure that it gets below the The Mating surface I'm going to reach in there and right there bust off the bottom of the Helicoil [Music] and that's it eight more there four on the back thread work at least on the turbine housing is complete it's the same thing over and over for the rest of the turbine housing repair that's what we're doing there we'll move on to the next component component number two turbine wheel we've got Max turbine wheel chucked up in the Super Tech cylindrical shaft grinder this is a extremely precise Machine Tool and extremely critical component and dimensions during the inspection process we determined that the turbine wheel showed enough wear where we were going to have to machine it we have gone to the warehouse and determined that we only have one option for undersized Journal bearing the shaft wasn't that bad we normally would go in increments of five thousandths of an inch under size those are generally the nominal dimensions of custom bearings but again as we've discussed product support is non-existent the only bearing we can come up with short of manufacturing our own is ten thousands undersized on the shaft OD nominal Factory specification is from 0.7997 to 0.8 even Factory tolerance three ten thousandths of an inch we're gonna grind this shaft ten thousands undersized and we're gonna try and land between point seven eight nine seven and point seven nine zero and again the material that we remove with the grinder we're gonna take up with a custom bearing again this is precision machine work here we're gonna zoom in and let you watch an expert grind this shaft under size and you'll see it happen in probably a number of different bytes we'll get it undersized then we'll take it over for the last tenth or ten thousandth of an inch it'll be a hand polish and we're looking for final Dimension and surface finish all get out of the way and I'll let the experts do their craft you'll see him hit both journals with each byte parallel or concentricity or the equalness it's imperative that both journals are done on the same planes take one bite there how big of a bite are you taking one at a time all right so again we're shooting for a ten thousandth undersized bearing the shaft had probably a thousandth of wear in it and he's taken bytes of about one thousandth at a time so you'll see the shaft come off after each bite so he'll knock it down a thousandth come over take a reading on it figure out where he's at a lot of back and forth we won't show you the whole process but he's watching it extremely closely right this thing is unobtainium at this point if he smokes this one the project is delayed cannot order up a new shaft no pressure on the master but I have no uh concern that this thing won't be brought right back to life gonna dial in another thousandth of an inch and he's hand feeding across it so he's keeping an eye on it compressor side Journal walking up on the turbine Journal and he's going to walk it up just as close to the back of the head of the turbine wheel as he can get it watching her like a hawk and there he's done you come back down he knows that he's got enough meat he doesn't have to measure it every step of the way but he'll keep a close eye on it roughly 10 passes across the cylindrical shaft grinder when he gets closer to the end he'll make much more frequent measurements and we'll make sure that this thing lands on the exact specifications again tolerance is three ten thousands of an inch right that's four decimal places roads he'll nail it again he'll leave one tenth possibly for a hand polish and then once he gets this thing dialed in we'll move it over to the shaft straightener and the balancers we'll follow this thing through the process step two turbine wheel so we did the grinding undersize we've done the Polish jobs the material that needs to come off of the shaft has been removed the next step is the straightener these things turn pretty rapidly even this old Pig you might be talking 20 or 30 000 RPMs Straight Shaft is a critical recipe component for a long living turbo balance is critical and shaft straightness is critical this old dog looks kind of crude but this is an extremely precise hydraulic press you can see there are three different dial indicators chucked up on the shaft we're going to rotate the shaft in these fixtures read the indicators again we're down in tenths so four decimal places we're reading the straightness or the run out on the shaft I have no doubt that if I were to attempt this I would immediately destroy this component again this is unobtanium makes me a little bit nervous to watch these guys straighten this shaft but they're going to do it all right it's chucked up we're going to watch an expert spin the shaft read the gauges Mark the highs Mark the lows you'll see them Slide the turbine wheel back and forth down here is the business end so you'll get to see him give her some beans and we'll straighten this thing back out once we get it straight we'll take her down to balancing we'll step back again and watch the experts perform their craft tell fired up he's giving her a spin job again marking highs so he's made his reading dial in how much pressure he wants to give her give her the beans this is touch and feel and experience so we put a little pressure on her slide her down to the next High there you go and then we'll spin it check it again to see where we're at and then we'll likely chase our Tails a little bit we'll just keep going after the highs right knock down the highs read it again looks kind of crude but shaft straightness is Mission critical so get out of his hair not apply any pressure let him finish getting this thing straightened up and then we'll take you over to the balancers we'll bring you along step three in turbine wheel Reclamation also using a machine that I know nothing about this is a Heinz balancing machine it also is from an era before but this dude is also extremely precise doesn't look like much but it is more so than shaft straightness balancing is a critical component for a quality repair and this is where it happens this is the balancing machine we've got a turbine wheel chucked up in it right here we also balance compressor wheels or we'll also balance them as an assembled unit compressor wheel on the shaft potentially the thrust components chucked up in it as well for sake of video we're going to show you the turbine wheel all right again this thing is one of those magic boxes I don't fully understand how it works I know that you use some of these dials over here to tell the machine the characteristics of the turbine wheel real diameters and lengths and weights and things of that nature are dialed in on left and right plane we've got a book here from before I was born for this wheel that tells us what some of these readings should be the wheel is chucked up on these rollers and it's a little bit floppy in there okay what this thing does is it detects the high spot so when we get out of the way and shut our mouths and watch a professional do this he's going to take some of this shmoo and he's going to stick it on the wheel that's going to dictate where the high spot is he's going to hit the contact button and run this thing up and he's going to dial it in so the strobe light indicates the high spot or the heavy spot that we have influenced with the tacky weight okay then we're gonna pull the tacky weight off and we're going to run it again and that's going to reveal the true heavy spot once we learn where the true heavy spot is where the imbalance is coming from we're going to take the wheel out of the fixture we're literally going to walk it over to a grinder and we're going to remove material from either the left or right plane depending on the readings and either a little bit or a lot and even a lot isn't much in this context we're going to knock some weight off of it with a grinder once we do that we're going to bring it back over we're going to Chuck it up again we're going to run it again and we're going to find the next heaviest spot and we're going to be able to tell on this gauge how heavy that is there's a specification for imbalance and we're going to get beneath it that's the goal get the imbalance out of the wheel so that when this thing goes back together she hums along beautifully so again we're going to get out of the way we're going to watch an expert do the balance thing on with the sticky weight he's going to runner up he's going to dial in the speed speed is what determines when the strobe lands on the sticky weight so he's trying to get the sticky weight at 12 o'clock it's kind of like an ignition timing light from the back side you can see that he's got her dialed in at 12 o'clock that's step one kind of a calibration for this machine get the light landing on the heavy spot now pull the weight off you want to make absolutely sure that you get all of the sticky off of the wheel because if you leave some introduced weight on the turbine wheel it'll throw your reading off weight has been removed he's going to run it up again and he's going to turn the strobe on he's reading the gauge to see how much imbalance he has and he's looking at the back of the wheel and you can see some of the prior balancing marks so that's how he knows where to go and remove some materials he's going to walk it around he's going to mark it that's where it's heavy run it again and verify that his Mark is at 12 o'clock it dances around a little bit so you kind of have to take an average but he's got it nailed it is on 12 o'clock I don't know if that's picking it up but you can see his Mark right there in the 12 o'clock halfway up the back of the wheel and he's also checking the left and right plane both sides of the head of the turbine wheel are being measured here that's the first step now we know where the heavy spot is we'll move it over to the grinder look at the grinder that we use for removing material from these components well this is not the one to be using to sharpen your drill bits or grind off your weld splatter right this thing's got a little bit specialized wheel this is only for shaft and component balancing we're going to take a little bit of material off of this one and we'll run it again that's it that's all it takes so you saw it pulled some material off on the grinder put a little schmoo on the bearings there daughter wound up the speed and now he's got the balancer engaged and he's reading out on that dial how much imbalance is there he cut it down to a fourth of what the imbalance was before and he is in specification by twice as much as it should be so turbine wheel balance this thing is ready to go we'll clean it up and do just a final inspection but this component is ready to be handed back to the build up rooms we're back in the machine shop for the bearing housing work this is a miltronics ml22 flatbed CNC lathe this is where we do a lot of bearing housing and then housing work we've already got this bearing housing chucked up in the spindle that's mats bearing housing that's the one that was worse for wear this is the bearing housing out of Plan B so Gary's already got it chucked up and dialed in true we're going to use a boring bar with a carbide insert specifically for cast iron again we spoke of this Step at the counter right this one's not exactly traditional design usually we would just come through with a hone smoker out square and we'd be good to go this one's got this step that we discussed either Machining out and putting a snap ring groove or what we're going to do boring bar we're going to walk up to that step and we're going to skim the idea of this bearing housing he's got her touched off and dialed in and he's operating in conversational mode no program from the development office he's doing this one right on the keypad we're going to get out of the way we're going to watch this thing get cut back to factory spec all right so here he is chucking up the bearing housing in the lathe once he likes the way he's got a hold of it he's going to start taking some readings making sure we've got it dialed in got a test indicator on a MAG base you'll see him check it in the X and Y directions here so rolling it around watching the highs and lows on the indicator remember the attitude adjuster knocking around spin it again look for the highs and lows shooting for zero [Applause] looks good in that direction gonna clerk her down in there put the indicator around and read it in the other direction free jaw Chuck but it's a it's adjustable so kind of like you've seen a bomb doing the four jaw thing this is an adjustable three jaw so just roll it around check the highs and lows knock down the highs loosen the loads make an adjustment roll it around check the indicator [Applause] nailed it now he's got the bearing housing chucked up zeroed out and he knows where it is now the next step is we have to tell the lathe where the bearing housing resides in relationship to the tooling to zero it out if you will hone it in however you want to say it but we got to tell the lathe where the part is so he's already taken a measurement he knows the distance from the outer face down to the step so really he's just looking to tell it the diameter of the bore and the location of the outer face looks like he's running a reference tool he probably knows the diameter of that little widget and he's going to put it in between the tool and the part and then compensate for that on the dial pad here so he just dialed in a quarter inch so he is in programming mode now he knows the dimension of the current bore he's told the machine where the bore is located he's told the machine what the bore measures and he's told the machine how much he wants to take out I don't know if the camera is picking it up but you can hear it just faintly cutting so we're taking about five thousand to pass here and again because of that step we're not going to get the opportunity to run a home so we're hoping that the surface finish with the boring bar is acceptable if not we might reach in there with a piece of Emery or a piece of scotch Sprite maybe give her a polished job on the lathe and if that doesn't cut it then we're going to have to smoke that step out of there and take it to the home take a look at her the snap ball gauge so he's going to take a measurement Tolerance on this Dimension is a half a thousand so five ten thousandths of an inch is Target snap ball gauge in a micrometer now we've taken a measurement after the first cut he's back on the conversational mode he's gonna update the location of the bore and the diameter of the bore and when we come in for the final pass we're not there's no guesswork left right we are now have a true cut with this bearing housing fixtured in this machine with that tool located where it is so now that we've updated that information we're going to come back in for the final cut it's somewhere around five thousands taking it easy on the feed rate [Music] again we're taking five thousands across what is probably a half inch Journal so this is not you know hogging a bunch of material this is pretty precise and again we've got a tolerance of a half bowel uh which is pretty generous for us right that should not be an issue to hit so all of that set up all of that blabbering for that right there right that's going to be what saves this Turbo so he's got that journal dialed in just to make sure we've nailed it once we get it off the machine once we've ensured that he's good to go here before he takes it out of the Chuck and moves anything he's going to want to make sure he nailed his Dimension over to the micrometer all clear Journal bearing Salvage so you just wash just skin that journal out he's looked at it surface finish is fantastic Dimension is spot on the real test this is the 10 000 oversized Journal bearing we've been talking about this throughout the entire process the clearance or the tolerance between the OD of the journal bearing and the ID of the bearing housing is about two and a half thousands he's measured the bore it's spot on for a 10 over bearing and we're gonna do the Layman's test right is this going to fit in the hole and is it going to slop around here we go the board is right here slides in perfect nailed it so that was side number one now we've gotta take it out of the machine we've got to change the Jaws we got a totally different fixturing on this side we'll flip it over dial it in again and we're going to come in from this side or the other side skin that journal bearing out repeat the process critical component of this operation is we don't only have to make sure that we're centered on the bearing housing but we've got to keep the journals in line with each other we can't have them stepping apart or tilting away from each other right they have to be parallel and directly in line with one another we're going to get out of the way Gary's going to flip this thing over skin the other Journal out and then the world will be saved Gary's got the bearing housing spun around looks like he's got the indicator dialed in on it again that side of the bearing housing had a good known register it was original Factory fixturing and machine areas he's chucked up on that he's dialed in on the back I would guess at some point he'll come around and reach in and touch the journal that he's already machined to ensure that we've landed correctly it's the journal on the backside that he's indicating with was machined in the same operation as the face that he's indicating and if the journal that he's going the machine on the outside was referenced from it then we know we're going to land back straight and we're going to land parallel and on the same planes it's uh Mission critical that those with those line up [Music] same thing on this side he's got the part Chuck in the in the Machine Tool he's got it indicated running dead center on the bore and then he's got to come over with the tool and he's got to tell the machine where the part is in relation to the tool again we're doing this through conversational programming right here on the keypad of the machine and he's coming in gonna touch off he's also got to tell it where that step is we can't blow through that step that's what holds the journal bearing on the inside of the bearing housing [Applause] he's using the hand pad there and he's just coming in and skinning a flat surface so he's got to get a flat surface while it's in the machine so that he can tell the Machine Tool where the bore is and what size it is he's got a depth mic here reach in and touch that step so he can tell the machine where that step is he knows some Dimensions he knows where this component is located he's telling the machine where these things are right again we can't smoke that step but just like the other side this is first cut so he's got it dialed in once he gets the first five thousands out he'll come in take a measurement at that point we know the gospel we know the dimension the Machine Tool knows exactly where the part is turbine housing side of Matt's bearing housing this journal was the worst condition and we've cut five thousands which is generally enough to clean up a normal failure still got grooving in the journal so it's cleaned up enough where we can get a good measurement enter those particulars into the programming the machine can tell from there exactly how much more to cut off to get us to land within specifications [Music] practice cut the cut to tell the Machine Tool where the part is was right on out of the gate because we were piloted off of a known good surface and in line with the other bore we've already cut it would stand to reason that that cut would have gone well final pass theoretically there you have it looks like it cleaned up so we're going to take a look at the Finish make a final measurement make sure we nailed it and this thing is almost ready to go back into service right on the money says the man fantastic [Music] we brought you through the process of saving the turbine wheel that's good to go we ground it ten thousands undersized we brought you along for the process of repairing the bearing housing and again we took the ID of the bearing housing ten thousands oversized so just like you've seen on crankshaft journals same thing right machine this undersized machine that oversized and then we've got a custom bearing to make up the difference the clearances have been restored to factory specification the components have been inspected and we are confident that they're good for another cycle of Life turbine housing not super proud of what we've got going on here but there's nothing we can do this is real world situation this Turman housing cannot be sourced if it could I ensure you we would get a new one but there are no used ones out there to be had and that's not even considering the condition right we didn't say we want a good used one we just said any used ones none there's none this is it we brought you through some of the process here I think there was about 12 holes the hardware was busted off set them up in the old Bridgeport knock them down drill them out Helicoil and repairs and the big picture in the grand scheme the hard part is done we're going to take these components back up to the build up room and we're going to spread them out on the table we're going to ensure that they are spotless and clean appearance is good final inspection we're going to get some components we've got Journal bearings here they've got some more parts up there and we're going to slap this dude back together and we're going to send it back to Matt we're back up in the assembly area a couple updates that we didn't bring you through in the Machine Shop the uh bearing housing out of the plan B Turbo was scrap says right on there no good we had this chucked up and we had too much run out in this flange in that direction it would not pass inspection no good on that one the outlet flange we showed this earlier it was cracked here no good drew it up we had the neighbors next door run this out on the water jet we've got a new flange I don't know why they've only got two holes in this land there's four holes in the turbine housing I would have put four holes in it but we don't know if the application has some type of interference if needed Matt can pop those out easy enough the turbine housing we did one more operation here where this flange mates up so this dude goes there that's where your exhaust system connects on the turbine housing out of Plan B we faced this area so we've got a good ceiling surface and then we came in on the back side where it bolts to the manifold and did some cleanup work there this is the turbine housing out of match turbo also no good so we'll move it down to the junk pile this is all scrap iron everything else on the table is ready to rocks we're going to get back out of the way and we're going to watch an expert slap this thing back together let's build a turbo here's the uh the vein like it goes in it gets these lovely wedge bolts [Music] foreign [Music] place um we replace the gasket for the little shimness on the outside so those wedge bolts capture the nozzle ring and the nozzle ring in this configuration is interchangeable and is what dictates what we call the AR of the turbine housing or the flow characteristics thing you can you can swap that out to kind of change the performance it is the original variable geometry even though it cannot be very tricked right [Music] all right um at this point I'm going to install our shims the original shim if you remember when it came out in the video they were all rusted and corroded we have these made for us these are kind of hard to come by I can go ahead and this this is also the material that we machined off of the face of the bearing housing where it was not true this is what we have to use to make that back up so correct and then this is a heat shield I'm gonna go ahead and install this piece here and I can set that piece aside next is getting the bearings all installed into the bearing housing here's where he was just talking about where we machined the face off this bearing housing compared to the old one when tested although look worse it actually function much better so that's why it was retool to be reused just giving my services a wipe down we coat stuff in a coating oil so that way they don't instantly rust we had to cut the bearing housing out tin and we had to also grind the shaft of the turbine wheel downtons my bearings we call them 1010 and that's to make up the material that was removed in and out I give them a good coat of oil and that just slides right on in there next piece is um it's a very small thrust bearing and it goes it's pinned um it pretty much only goes in one way if we were to put it the other way it would not be aligned correctly then we have what I call a flinger it's also sometimes called a Slinger it cleaned up pretty well and then we have a new piston ring so I'm going to put the string in a screw we replaced the original seal plate it had damage here with a where the original Slinger had pushed up into it so that just kind of snaps up in there feels good all right um I'm gonna put a little bit of oil on the top of my thrust bearing and then there is an oil hole this is where your oil comes in that hole aligns with the hole on the seal plate pull off the oil to get there if you don't align that she will not last very long yeah she the turbo will burn up self-destruct very clear yeah very quickly within moments these are the components that were the root cause failure of this thing right so we discussed oil contamination before yes and these are the components that took the brunt of it I got some better better shims that go here um it's just held down by at least six bolts all right here and tying most of my stuff down so that way what I don't want to do is just tighten one side it could then kind of make the seal plate and even though everything will tighten down it's not sealed flat and true and then later in the stack it could just cause issues so just trying to get it right here is pay as often here the proverbial star pattern just like you need Mount Your wheel back on your car right you don't zip one down and then yes correct torque it all the way right and let's get them all snug and then come back yep so I walk them in yeah I do that pattern a couple times and make sure they get a little snug as we go I'm just going to torque them to it's about 120. it's good that's good and tight then these were installed with these uh I call them bendy tabs um and then I just I'm building this tab back up this helps these bolts not to back out on themselves technical term bendy tab technical term bendy tab um I think so the correct term is lock washer but I mean I'm with you it's fun bendy tab I think everybody understands that a little better maybe I see a lot more of these type of tabs usually on the on the turbine housing and I it's just the vibration of the turbo usually external to the turbo but you can see if those bolts come out inside the turbo you're going to have a bad day that is also very true all right so those are all been bent up we're gonna flip it over what I call the top bearing it's just it's the turbine side bearing it's the hot end same with last I'm going to coat it with oil just kind of slip it in there this side gets a retaining ring the other side did not need a rotating or even the way it was stacked up that thrust bearing when it's pinned down kind of held hold that that retaining or that journal bearing in place on this side it does not have anything to stop that so if we just put the wheel in there that journal bearing would lift up and so the the inner edge of the bearing is retained by that step that we've discussed when we were talking about Machining the bearing housing it had that step which is a little bit unique to this style usually there's a snap ring on the inboard side and the snap ring on the outboard side yes you have the inboard retaining feature is machined into the bore of the bearing housing that feels pretty good bearings are captured Journal bearings are captured correct next next is our diffuser plate it's a unique vein system setup I guess on this as well you don't normally see the helping airflow on both sides it's usually just on the turbine side that feature is long since obsolete right that's discontinued it's no longer something you see in a modern turbo yeah I have nothing on a modern um even the New Year the newer vgta turbos and all those they're all it's all in the turbine housing it's not over on the cool side so as we tore down we didn't mark the housing what I am actually doing I've uh realigned it and yes because there's four bolts here um if I if I change it it will change how the oil inlet and our discharge aligned to the outer ring bolts which then can change the orientation when it's placed into the compressor housing we're going to give it back to Matt yeah so he can just he doesn't have to do any extra hard work right yeah so it's important that you pay attention to the correlation between these components because if you do not Matt goes to bolt this on the engine the oil drain is pointing up not at the lines or the compressor discharge is not pointing towards the intake piping right so way back when we first started this project they took a chisel and they whacked some lines into all these different components so that when this day came we knew how to put them back together yes and that's um something we do When anybody sends their turbulent for us to look out uh it's that's usually step number one is please mark the housings that way later down the road if it is repairable we can do that the customer won't have to do any more extra work there is an orientation specification outline in the manuals on this but oftentimes the expectation is that the orientation has changed on engine or on job site so we always Mark the way that they were when they came in it is common practice in the turbo replacement world to have to re-clock one of these housings or two of these housings right we get the phone call every week hey you sent me the wrong turbo sure and no um we didn't that's the way it's supposed to go out and when you hang the turbo the expectation is that you do the housing adjustments so yes we try and mail them when we know but oftentimes we don't know what they're going to go on I do these bolts in any bolt that takes a back plate similar how to seal plate I take them down just so they're kind of snug and then I do another crisscross or Star pattern is deer coming on our bolts same reason we don't want it to be slanted anyway we don't want to just pull all the one side it all can just in the end cause issues and it can just be right here just because you didn't you try to go a little too quick kind of like building a house start square and square right that's if you lay the foundation and she's Cali wonked you get to the Finish Line you're gonna have to take it back apart I took these to 150. pretty good all right almost have a cartridge built up the cartridge is what we call the bearing housing and the wheels in an assembled State some some folks call it a chra center housing rotating assembly uh or a cartridge and it's a common service process right so the end housings are just boat anchors and if your turbo fails in the field you can slap a new cartridge in your existing in housing so right so this is another this is called a diaphragm it's similar to a heat shield it's it's a tier [Music] I just have those there to help align and then this this particular one kind of gets a this large nut spun down on it most heat shields well most most turbos on in newer stuff don't take a lot of diaphragms and so most heat shields just kind of sit there they might have a retaining ring on top but not really like this [Music] but I'm checking here is I want I want to know that this this large bolt is equal or flush to this surface so I'm gonna tap it a little tighter [Music] it feels pretty good there is a very small shim that part of it and it kind of gets lifted up into this place here technical term bendy tab bendy tab except it's more like a mini shim I guess bendy shim bendy shim and its purpose is just like the uh the Bendy shims the bendy tabs it helps us if it if the vehicle is gyrating enough on application it won't work itself backwards yep locking mechanism right retaining feature foreign wheel newer turbine Wheels actually take a piston ring the style these old turbos don't actually have a piston ring here so all I'm going to do is Luber shaft up and then I'm going to go get our compressor wheel so this this kind of goes to show that back in the day they didn't even have a seal on them so we've talked many times about hey my Turbo is leaking oil I think the seals are bad right and it's highly debated topic but the seals are not really what keeps the oil inside the turbo it's the differential in pressure and uh the piston ring is just kind of a suggestion that it doesn't leak but very important piece it's just called the shim the shim the shim so we talked about this before this is what dictates the position or the depth of the compressor wheel into the compressor housing yes so all right we gotta get the wheel all right so the Assembly of this turbocharger calls for a preheat on the compressor wheel so it's kind of an interference fit and the compressor wheel is in the oven right now we've got a guy going after it we've got the majority of the cartridge assembled and fixtured in the turbine housing holding fixture moments from now a hot compressor wheel is going to come flying in here and hopefully she slides right down on the shaft that's got some movement on the other side of the bench and there comes compressor wheels so okay I'm also going to be putting Loctite and there's also um a washer another important piece these are just little washers they help keep everything locked in place don't want this thing to come tumbling out of the fixture as you're well aware by this point this this is unobtainium stuff yeah so if you would like to hold on there I'm going to take it to torque now so that's a good sign that it spins that means that so far nothing that we've built up is causing any type of lock now we have a cartridge now we have a cartridge a cartridge it's a wheel to wheel completely built up our next up if you want to give it a name it's the super core again he's looking for the orientation marks because this thing needs to go in in a particular position correct and I would like to show the marks if I can here was the marks that we believe our tear down guy did I believe it was finally Detroit and so these marked up when I tear down a turbo or r r i Market to our oil inlet which I have written here because I want to be 100 sure on this put some bolts in and it's just like seal plate and the diffuser plate I'm going to get them hand tied make sure everything aligns up well they did not scrimp on the bolts in this connection there's I don't know 16 of them there okay let's see here there were 12 12 studs that had to be replaced plus 12 volts on the outer ring none of them were good out of a tear down we we do try to replace all bolts we it's good practice Yeah I want fresh Hardware yeah okay so those have been tightened torque down on at this stage I like to give it a spin I don't feel any fines or anything at this point I am going to install a drain plug I just like to do that now then we have a turbine housing it's important to the turbine turbine housing turbo so here we go she's getting some hefts now you can see he's also paying attention to the orientation again [Music] and I'm going to check my orientation I did make notes oh good okay also giving a spin to make sure that while it's in here that we put enough shims this the T line T14 and the t30s are what I know um if you were to get the here and our Wheels hitting take it back out gotta add another shim put it back in we would tighten it it would repeat this process and also those two mating surfaces that he just joined together have been machined on right yes even if originally it called for thirty thousands when we fixed that bearing housing we skinned 60 off the face and I think they went in and touched the mating surface on the turbine housings let's go he made a educated guess when he went together when he started the inspection and reassembly process and the measurements and then predetermined what that number of shims would be would you end up with three I ended up two fatties and a skinny in there correct yeah I believe when the book talks about it the fatter ones or twenty thousandths and thin ones or tens but we had created thirty thousand and then this process is just like everything else I'm hand hiding bolts then I will go back around and make sure everything's is seated correctly also bendy tabs bendy tabs can't get enough of them so if if you have the turbine wheel too far away from the turbine housing you'll lose some of the ability for the exhaust gas to drive the turbine wheel yes um on the other end of the spectrum if you don't have enough clearance and the turbine wheel can come out and contact the turbine housing it's important right you don't want either of those situations you can see some of those studs reaching up and impeding the oil inlet and Outlet the final step of this or one of the final steps is to get this thing tightened up need to come back and Lop off the top of those studs yes but before we go to lopping we want to make sure this thing builds out correct so yeah you don't want to do all that now to find out later wait a minute you also want to make sure that you have those oil connections plugged before you go to grinding and shooting Sparks into this thing right yes contamination is why it showed up we don't want to contaminate it before it even leaves the place it corrects yes um as soon I had plastic trays to keep my parts and I try to I try to keep anything that could become a contaminant to stay a wave and that's where my bearings my thrust bearings any of the internal parts yeah a little bit a little bit more cleaner operation here in the build up area than it was you guys saw the dungeon out there in the teardown oh yeah you don't want to be assembling turbos out there it's it's full of contaminants and yeah I just I walk out there and I'm instantly dirty somehow yeah all right so I tightened every other one now I'm just gonna go in reverse order and do the exact same thing I'm checking my wheel as I do this because now that we're tightening it we are bringing it down onto some shims we just want to make sure that we still have clearance and it's an important that's an important thing because if it's con if it's making contact and he doesn't know it and he's winching it in with this with the bolts yes it's going to damage the turbine yeah so we definitely don't want to do that and see him as he goes every so often he'll reach in there and give it a spin just make sure it's still free and that also helps me like if I know that if I tight and say this one here and it locks then there's possibly an issue it could be cocked yes you know so yeah this this model this era this technology these are a little bit uh cantankerous Builders sometimes right the newer stuff when when the components are more fresh and the Machine surfaces are still pristine right those dudes slap right back oh yeah yeah these are these can be this wasn't this wasn't too bad but we did do a lot of work to it yeah um not that we don't do a lot of work the other ones but they can still be kind of a drag so this is why he was so cautious when he first started going together that he had things square and true because he doesn't want to take it apart again you don't have to so he knows he's had to take him apart before pay attention out of the gate start off Square end up squared so yeah they don't get any lighter as you go no just gets heavier at this point I'm going to I still got to spin got my oil living over here I'm going to rotate it when it's on the vehicle it would be spun a little bit more for a foot I'm just getting a feel for it it feels very nice I'm going to put a little oil in the oil intake but not much what do you got in the container so I like to use Lucas oil it's good for your engine but also it has just the right amount of attack that when building some stuff it can help just heavy weight yeah heavy weight and sticky stays where you put it right and that's prelude's important as well guys and and some of these turbos even from manufacturers today come from the factory dry and if you don't get oil to them real quick and fire up the engine it'll destroy the turbo so we always throw some in it while we're assembling it yes we are Advocates of pre-lubing it on the engine before you fire it up yes hopefully when Matt gets us back you know he pulls the cap out he puts some oil underneath he just works it in as well I can fill this all the way up but it's got to go all the way back to him and it could we don't want to ooze out it'll leak out before it gets there again this thing doesn't have the it doesn't have the pressures that are keeping the oil in it at this point on the bench and and by Nature I know we discussed it a little bit earlier in the video but by Nature this thing is going to leak a little bit until it soots up and until he works the machines so we've we've discussed it with Matt right need to change your oil and you need to put this thing on and kind of go to work fairly quick get some get some heat in it and get some dry pressure behind it yeah so I put mini tabs it also has lock washer so I'm just gonna see if I can bend our tips up just a little bit um and then there's a few other things that will do and this will be good um like I said I'll cut the tips of our studs off because it does feel great and I think we're I think we're good here one of the last pieces of the puzzle is to dress her out one of the few remaining supporting suppliers out there is in fact caterpillar themselves they don't have a whole lot left for this pig they do have the the installation components um I will tell you that this box of seemingly simple components three gaskets and uh six O-rings probably costs about as much as your average turbocharger today wow brace yourself if you're gonna go there but these are unique to this turbo this turbo is 60 years old caterpillar does still support these components they are proud of them we'll pop these on we'll ship out with the turbo the oil inlet oil drain and foot gasket we'll throw the O-rings on the compressor cover and we'll move this thing on to the next step so the master is done the last step of the process is to identify this component down the road we want to know we want traceability as to how we fixed it who fixed it what components went into it this is all documented in our business system and the next step is to identify this component we're going to go over to the laser we're going to engrave a data plate that identifies part number and serial number which again would lead us down the path of how we arrived at this component when we serviced it we'll do that we'll tag this thing and we'll take you back up to the parts counter and we'll get this thing out the door long process right but we've reached the ends at area Diesel Service one of the many cultures is do the best you can right and that's what we've done you guys watched it we don't have to go back over it yet again we've got an amazing crew back there you guys saw the process given the circumstances given the component availability this is the absolute best job that we can do at area Diesel Service and I'm proud of it these guys nailed this thing this is kind of undoable work these guys whip this thing back into fantastic shape that's where we're at I'm proud of the crew give them a thumbs up give them a like this thing turned out fantastic million dollar question summarize what did it take we had 11 different people touch this thing throughout the process those 11 people account for 227 years of experience one of the values of area diesel we've seen this stuff before about a 20-year average uh level of experience for the people that contributed to this repair you saw many pieces of equipment we didn't show everything but lots of expensive stuff required to perform this repair you saw the miltronics flatbed CNC lathe laser engravers the you know things you don't even think about right forklifts Bake Ovens Bridgeport shaft grinder shaft straightener balancer roughly speaking we tried to think about the equipment that we used well north of a half million dollars of equipment were utilized in the repair of this turbo a little bit of overhead to kind of give this thing some scale to summarize the expense the question that everyone is wanting to know what did it cost and we've got a list we had 215 dollars in some custom shims 625 was the teardown disassembly cleanup preliminary inspection 625 dollars the plan B core 500 dollars in other words a bag of gaskets from Caterpillar that was 175 we had to make a discharge flange that was another hundred dollars kits bearings internal components 260 dollars the thrust plate that was smoked out of Matt's turbo Buck 85 hardware and helicoils forty dollars the trip through the Machine Shop big line item here sixteen hundred dollars to perform all of the machine work and Repair on the sub components and then we had another hour of Labor to put the thing back together grand total thirty eight hundred and twenty five dollars to fix this 60 year old turbo for what is likely about a 3 825 dollar bulldozers that's why you don't see too many of these at area diesel anymore but occasionally they still roll in we'll drop you a link to our merch store if you want to check out some area diesel swag again if you see opportunities for us to collaborate with other YouTube creators tag us in a comment take a screenshot shoot it over to Parts at ariadiesel.com we'll send you out some of that sweet area diesel merch no charge if you do need any of our services and you mentioned to us that you learned of us through this collaborative content with fellow YouTube Creator diesel Creek we'll send out your project free of charge on the shipping and if you need anything don't hesitate to reach out to us we pride ourselves on taking good care of folks providing a high quality customer experience you can send us an email at Parts areadiesel.com you can log on to our website at areadieselservice.com where you'll find a large amount of high quality information you can chat with us instantly through the button in the bottom right hand corner of your screen where you'll have immediate access to a diesel engine expert or you can call us at 800-637-2658 or you can stop by any of our locations in Iowa Illinois or Indiana and the first person that sends us a fax with their name an address we'll send you out a hat right 217-854-8972 shoot us over a fax we'll send you out a free hat so that's a wrap we appreciate you watching we'll see you next time foreign

Channel: Area Diesel Service

Views: 279,495

Keywords: DieselCreek, diesel, creek, matt, mattdieselcreek, siezedengine, construction, landmover, land, mover, free, rust, oldiron, old, iron, rustoration, restoration, willitstart, 6-cylinder, six-cylinder, six, areadiesel, howto, series, fuelinjection, injection, pump, DBG, DBGseries, vintage, reman, remanufacturing, rebuild, repair, replace, horsepower, fuelplate, turbo, dieselengine, dieselenginerepair, smallbusiness, mechanic, dieselmechanic, heavy-duty, equipment, increase, garage, Cat, Caterpillar, D8, D8H, T14 Turbo, T14, T1404, bulldozer, dozer

Id: zAx5ZdDD8fU

Length: 116min 5sec (6965 seconds)

Published: Sat Aug 05 2023