I seem to have lost all boost

[Shadow351]

So I was in Indiana today and was going up a grade and heard a chirp/bark as I was on the throttle and the car fell on its face. I let out of it and got back in it and it was seemingly happy again. Over the next 50 miles or so, this happened a few times then eventually it never recovered. It now has to drop to like 2nd gear and wind out to over 5000 rpm to make it to 75mph. I only had my blue driver with me and it doesn't have a 'boost pressure' PID (I'm not sure this car has one) the closest I could find was the MAP reading. I monitored the MAP reading on the rest of my drive and never saw it go above 30 inHg (an arguably worthless unit, I had to convert it to something useful ~14.7psi so atmospheric pressure?) and only heard the BOVs (VTA modded) open like twice in 150 miles and they only emitted a small hss as opposed to the usual pop-hisssss (these are technical terms). The first thing I checked was the noise maker and I cannot blow through it, but I replaced it with a plug anyway, no change. I pulled both BOV's (originals dated 2009 with ~274,000 miles on the car) thinking maybe one was sticking but they both push in smoothly and spring back out on their own. I did jumper them with battery voltage and they don't move unless given a slight push, then they pull in and hold until voltage is removed. Is this how they are supposed to operate? I also pulled a vacuum on the wastegate control and it held 20 inHg so not a leak in the wastegate control lines. I then smoke tested the intake and didn't see any substantial leaks (a small wisp was coming around the boost reference line but not enough of a leak to cause loss of all boost.

Any thoughts on this? Has anyone experienced similar total loss of boost? What kind of MAP readings should we be seeing on stock tune? (I think I've seen my dad's Ecoboost F150 hit 30+ psi at the MAP, but I know the trucks have bigger turbos and are tuned different)

Edit: I got my Autel out and confirmed I have a P0299 Turbocharger A Underboost condition. Blue driver did not pick that up and no check engine light?

 

[Texas Marauder]

Sounds like a large boost leak somewhere. Here is the pinpoint test for P0299.

 

[Shadow351]

Thanks, I'll go through that today if I have time. I did throw a pair of BOVs at it last night because I could get them. No change. I'm at work right now and just had a thought, I've seen some codes that 'lockout' when set. Does the code need to be cleared for it to try to build boost again?

 

[Shadow351]

Well, that's not what I wanted to find....

 

[76FoMoCo]

Definitely lightly toasted. Sorry bud.

 

[SM105K]

Those are the stock turbos with 275K miles on them? WOW. If that is the case, they don't owe you anything. Sorry bud.

 

[Shadow351]

No, they are Ford replacements though. That one has about 50k on it. The original lasted ~220k, so I'm quite disappointed in the replacements. I bought that one in 2020 for ~$650. I just checked my Ford dealer and they want ~$1300 for one now and considering this one didn't last, I'm tempted to try and aftermarket turbo.

 

[Bronco2fan]

Gearhead is always an option if you have the time.

 

[SM105K]

No, they are Ford replacements though. That one has about 50k on it. The original lasted ~220k, so I'm quite disappointed in the replacements. I bought that one in 2020 for ~$650. I just checked my Ford dealer and they want ~$1300 for one now and considering this one didn't last, I'm tempted to try and aftermarket turbo.

I understand completely. My Focus has the same turbo and still going strong at 186k miles. Stock clutch too...

Literally just changed the oil, and trans oil before I posted this response.

 

[Shadow351]

Gearhead is always an option if you have the time.

I really need the car back up ASAP. I'm working out of state for the next 3 weeks, and can't put all those miles on the 'new' truck. Also, Gearhead's website says the turbos start at $3400, 'require' a gearhead tune, & replacement manifolds. It'd probably be over $4000 when all said and done. I also have some reservations on tuning an almost 300,000 mile engine.

I'm leaning toward getting a Dorman 667425 (I know, vomit, right?). But, it's $580 shipped, includes gaskets (and gloves for some reason), has a lifetime warranty, & no core charge so I can have this one rebuilt and on hand in the event of another failure. The only concern is "Made in China".

 

[SM105K]

I really need the car back up ASAP. I'm working out of state for the next 3 weeks, and can't put all those miles on the 'new' truck. Also, Gearhead's website says the turbos start at $3400, 'require' a gearhead tune, & replacement manifolds. It'd probably be over $4000 when all said and done. I also have some reservations on tuning an almost 300,000 mile engine.

I'm leaning toward getting a Dorman 667425 (I know, vomit, right?). But, it's $580 shipped, includes gaskets (and gloves for some reason), has a lifetime warranty, & no core charge so I can have this one rebuilt and on hand in the event of another failure. The only concern is "Made in China".

I 100% agree with this.

 

[76FoMoCo]

Make sure you clean or replace the oil feed line screens when it's done.

 

[Shadow351]

The screens come in 2 packs, I'm pretty sure I have a spare screen from when I installed this turbo.
EDIT: Yep, I have 1 AA5Z6C683A listed in my inventory spreadsheet.

The most irritating part is the bearings didn't fail, the seals weren't the failure....THE FRIGGIN NUT FELL OFF. Hopefully the guy at Honeywell in charge of tightening the nut isn't the same guy in charge of the Jesus nut on Helicopters.