Multiple Turbo Failure

[Blue703]

I am wondering if anyone is having repeated turbo issues. I have a 2011 SHO with only an AIRAID CAI. I purchased a tune from a reputable company...it was one of the two companies that most people on this sight recommend. It was a canned tune so nothing crazy. I hit 100K last summer and one of the turbos failed. The car was still under it's extended warranty so I removed the tune and brought it into the dealer. Was replaced and got it back. Put the tune back in. About 2 weeks later, the other turbo went. Repeated the same steps above. Didn't think much of it as this second turbo was old also. Got the car back and put the tune back in. Figured everything would be good since I had 2 new turbos. Well was I wrong, 3 weeks later, the 1st replaced turbo, failed. Repeated the steps above. Got the car back and guess what happened a few weeks after that...yup, the other turbo went. I am on the 7th turbo, 6 and 7 went about the same time it was so close. The dealer has tried to figure out why these turbos are failing, but no smoking gun. Everything is working as advertised. From talking to the dealer, they were saying that when the techs were researching it with other dealer, there was one case that took 4 replacement turbos before getting 2 that were solid. I am just shaking my head with this car wondering if I should just cut my losses. Something I didn't realize until talking to the Tune company, all these turbos are rebuilt turbos, not brand new ones. I am wondering if the rebuild company's QA is up to par?

Any help on this would be greatly appreciated!

 

[mrhighcaliber]

Interesting. What oil brand, weight and change interval are u running? Also what is the mode of the turbo? (Bearing Noise, seals blown/smoke from exhaust) The primary causes of premature turbo bearing failure are lubrication or cooling related, or a combo of the two. Next it would be seals. High oil pressure, and excessive boost pressure/heat would be the main causes of seal failure in my exp.

Sent from my Nexus 6 using Tapatalk

 

[SHOdded]

They have analyzed the oil for metal fragments? The fact that Ford has agreed to replace the turbos that many times without having an engineer look into it is not confidence-inspiring.

 

[The Gemini]

If I were you , I would start with the most likely culprit - the tune. Not bashing any company at all, but usually when things go wrong after people install aftermarket products (be it cars, guns, homes, ..... whatever) the first thing to do is take it back to stock. Then if the problem goes away, voila! Problem solved, and it didn't cost you a thing.

I understand 1000's of tunes get installed all the time, but that doesn't mean you didn't get a jacked one. Take the tune out, and then see if the turbo's continue failing.

Also, as SHOdded mentioned, you are running the correct viscosity and spec motor oil, right?


II

 

[Blue703]

Interesting. What oil brand, weight and change interval are u running? Also what is the mode of the turbo? (Bearing Noise, seals blown/smoke from exhaust) The primary causes of premature turbo bearing failure are lubrication or cooling related, or a combo of the two. Next it would be seals. High oil pressure, and excessive boost pressure/heat would be the main causes of seal failure in my exp.

Sent from my Nexus 6 using Tapatalk

I told the dealer to put their highest quality oil in, manufacturers recommended weight. As far as interval, I haven't had the car for more than 4 weeks at a time before the next turbo went since last summer, so... The tune company recommended using Mobil 1 but I never had the car long enough to get around to getting it changed.

As far as how the turbos have failed, you name it. I have had some that were blowing oil out the exhaust...one of them so bad, I blew about 2 or 3 quarts out of the exhaust before limping it home. A couple the dealer said the vanes were just destroyed. Another was screeching any time I touched the gas, I brought it in right away, the dealer said one of the nuts that is on the shaft was loose, so they replaced that one, that was #6. After #5 was changed, the rpm started to surge under acceleration. I would see the rpm ratchet up as the turbo would surge. That's the only way I can really explain it. The dealer kept insisting they had no idea why it was doing that. Luckily when #6 went I brought it in for them to look at. They changed number six and said the car was good. I took it down the road and brought it right back, it was still surging. They took it back and said the other turbo was bad and swapped it out, that was #7...

 

[Blue703]

They have analyzed the oil for metal fragments? The fact that Ford has agreed to replace the turbos that many times without having an engineer look into it is not confidence-inspiring.

They haven't said anything about metal in the oil. Was talking to the Maintenance manager yesterday, as guess what, it's back at the shop. Get to that in a minute. He said they had to jump through a ton of hoops with ford to justify the failures. Now here is why it went in, I started it yesterday and it started making a weird sound in the front of the engine. A sound like something was hitting the cooling fan (don't think that is actually what it was but, it had that metallic type fluttering sound) but, only when I gave it a little gas. It also sounded like I had an exhaust leak. Brought it to the dealer and just from listening, it looks like the sound is coming from the front/left side of the engine in the vicinity of the turbo on that side. They said they have to start pulling stuff out of the way to get a better look at it. I am waiting to hear the results. Guess what, it has been about 4 weeks since turbo #7 was swapped out...

As far as the dealer, not too confident with them but, here is my dilemma, my extended warranty went out a couple of months into this ordeal. But luckily these turbos are all being covered by the manufacturers warranty. Because they did the work, they are covering labor also. If I take it someplace else and they deem it an installation problem, they won't cover the labor, and who knows if the turbos will still be covered if it is deemed an installation problem. So staying with the same installer isn't costing me anything, except headaches...

 

[Blue703]

If I were you , I would start with the most likely culprit - the tune. Not bashing any company at all, but usually when things go wrong after people install aftermarket products (be it cars, guns, homes, ..... whatever) the first thing to do is take it back to stock. Then if the problem goes away, voila! Problem solved, and it didn't cost you a thing.

I understand 1000's of tunes get installed all the time, but that doesn't mean you didn't get a jacked one. Take the tune out, and then see if the turbo's continue failing.

Also, as SHOdded mentioned, you are running the correct viscosity and spec motor oil, right?


II

I agree with bringing it back to stock. I had talked a few times with the Tune company, they insisted it wasn't the tune. I agreed with them, so I was still putting the tune in. By number 5, I said, let me not put it in and see what happens. Well, like I said, that was after #5. I have already been through #6 and #7 with no tune and if you read above, waiting to see what happens with this new development. So I am leaning to not a tune problem. But I am really scratching my head.

As far as the oil, the dealer is the one putting in the recommended oil...

 

[glockcoma]

Has anyone looked at or changed the oil lines going to/from the turbo?
They could be clogged.

 

[Blue703]

Has anyone looked at or changed the oil lines going to/from the turbo?
They could be clogged.

Supposedly the dealer checked those after the first set of new turbos went.

 

[Terryy]

Maybe answer toward the end of this thread https://www.fordtaurus.net/forums/viewtopic.php?f=51&t=19854
His exhaust manifold was shedding metal into the turbo.

 

[SHOdded]

Nice find! Pics in this post:
https://www.fordtaurus.net/forums/viewtopic.php?f=51&t=19854#p120118

 

[Blue703]

Maybe answer toward the end of this thread https://www.fordtaurus.net/forums/viewtopic.php?f=51&t=19854
His exhaust manifold was shedding metal into the turbo.

Interesting, will have to ask the dealer about this. They have my car now. Apparently the turbo is fine, it just blew the seal between the turbo and the manifold.

 

[glockcoma]

Here's a pic I saved awhile back that shows the interior design of the exhaust manifold

 

[SHOdded]

Totally forgot about this pic, glock, good you posted it again

 

[brucelinc]

I am amazed that Ford continued to authorize the new turbos without demanding more investigation. I can't imagine the dealer being able to just keep throwing new turbos at it without Ford becoming involved.

 

[Blue703]

I am amazed that Ford continued to authorize the new turbos without demanding more investigation. I can't imagine the dealer being able to just keep throwing new turbos at it without Ford becoming involved.

I know, right...

 

[Tamara Dickson]

I am currently on turbo #5.. just blew it a few days ago... I just had a turbo replaced 3 weeks ago.. I am at a complete loss on what to do since I can’t afford to drop $3200 a month on a new turbo and no one can tell me why I’m going through turbos as fast as I go through men.

 

[luigisho]

Is there a warranty on those? Is the failed one the 3 week old turbo?

 

[Johnbigdog]

I am currently on turbo #5.. just blew it a few days ago... I just had a turbo replaced 3 weeks ago.. I am at a complete loss on what to do since I can’t afford to drop $3200 a month on a new turbo and no one can tell me why I’m going through turbos as fast as I go through men.

Welp, are you replacing the oil feed filter everytime? There is a filter in the feed line to filter contaminants. If you didnt have it replaced it may be clocked and starving your turbo. What does the engine oil look like? If there is debris in the drain tube, look for debris in the feed. Is it comming from.the turbo or before?

What does the turbo drain tube look like? Look for metal, make sure it's not restricted (not likely but something to look at) are you using the right gaskets?

Are you burping the cooling system, do you have coolant to the turbos?

What is failing specifically? Are the wheels contacting the housing, oil seals blowing out, is the shaft welding itself to the housing.

 

[Johnbigdog]

Welp, are you replacing the oil feed filter everytime? There is a filter in the feed line to filter contaminants. If you didnt have it replaced it may be clocked and starving your turbo. What does the engine oil look like? If there is debris in the drain tube, look for debris in the feed. Is it comming from.the turbo or before?

What does the turbo drain tube look like? Look for metal, make sure it's not restricted (not likely but something to look at) are you using the right gaskets?

Are you burping the cooling system, do you have coolant to the turbos?

What is failing specifically? Are the wheels contacting the housing, oil seals blowing out, is the shaft welding itself to the housing.

Beyond the above, is it the same turbo failing each time?