91.5 Auto 4X4 260,000 miles totally stock had 12 PSI boost last week on a 800 mile trip pulling a heavy trailer on the freeway.

This morning I was plowing snow when the truck starts to miss and smoke brown smoke that does not smell like diesel smoke, I lift the hood and find the hose from the air filter to the turbo is flat. I unhooked the hose from the turbo to see if it would clear up, it ran the same so I gave it a few blips on the throttle when suddenly the old Cummins is spinning like a Jet engine it sounded like about 5000 RPM, turned off the key and she just kept running for maybe 15 seconds then died. Sadly I needed a tow the 5 miles home but at least it was my other Cummins Dodge that had the Honors.
I just removed the pipe from the intercooler to the intake and it is full of oil, wiped it out and started it up to see if the high revs did any damage, it missed a little and cleared right up so it looks like the engine and Injection pump are fine but the seal in the turbo is bad.
I have 2 wastegated turbos I think are from second gens I picked up at a swapmeet would one of them fit and work right?
Can I put new seals in my stock one?
Should I look for a good used 1st gen turbo?
How do I clean out all the oil from the intercooler and piping?
Can a plugged air filter strain the turbo seals?
I have more questions but do not know what they are yet.
Any information will be appreciated.
Thank you Hyperpack

 

If the tube was collapsed then yes I would say the filter is clogged. Second, if the turbo was creating that much vacuum the seals could definitely leak the oil through. That may be your only problem. Pull the intercooler and rinse it with a solvent then cascade and water. The tubes and intake as well and make sure they are dry before reinstalling. Put a new aircleaner in it and try it. You may not need a turbo. Just check it really often for a while and at the first sign of oil replace the turbo. My 2 cents!!

 

remove the intercooler and flush it with hot water and tide or dish soap!


There's more oil in the bottom of the intercooler just waiting for you to release it with a nether blip or two of the throttle!

If the turbo shaft, don't have any more play, then the used turbos you have, the you MIGHT be OK after cleaning but........the plugged filter probably has damaged the oil seals in the turbo.

as far as the used ones, if its Hic it will bolt right up! if it is a whic or 35 then the waste gate my require some ext work to be done, to make it fit.


Flash

 

Sounds like the filter clogged with snow. A new filter may put you back in service once you clean the intercooler out.

The used turbos will work out fine if they have a V band style exhaust outlet, they will just require you to move the exhaust back an inch or so. You could also just swap exhaust housings and put the new turbo in your old exhaust housing, then it's a bolt-on.

 

Thanks Guys
The airbox was packed full of snow, First time it has done that in ten years of plowing, I did just finish a 70 hours of plowing in the last 4 days.

Would it work temporary if I rotated the outlet of the turbo housing and reversed intake Elbow then put a piece of pipe between to bypass the intercooler just like non IC trucks?
With the plow frame on it is a major PITA to get the IC out and if the turbo still leaked oil I would have to do it twice, I don't have a shop to work in and this is not the only broken thing I have at the moment.

Thanks Hyperpack

 

I dont know where you live. But if you need an H1C I have one you can have for the shipping cost if you want it. Ran fine for an H1C when I took it off.

 

No reason it wouldn't work if you could scare up the temp plumbing. Just watch that turbo seal for fresh oil....

 

What he said. Just loosen the band clamp and flip 'er around. Truck parts stores have charge air hose that will take the heat. Probably won't have EGT trouble this time of year.