Egt's and boost issue...

[rplowden]

Here's another one. My EGT's have been slowly getting higher. I use to see 300 at idle, easily. Now I'm up to almost 400 and it's colder outside now. I'm seeing upwards of 900 when accelerating to only 45-50 mph at no more than 2000 RPM. Also, I've noticed soot on the firewall, behind the turbo and I don't see more than 10-12 pounds of boost when getting into it moderately hard. I see 3 pounds when cruising at 60 MPH. As far as the boost, that's how it's been since I got it, but now I'm thinking it's low for the mods the truck has. Although, the turbo sounds what I think to be normal. Does all this sound to be related or separate issues?

My temp gauge is working and cycles as it should and the heat is working well. I know the truck has the upgraded 203 thermostat. So, I don't think the EGT's are related to a coolant system issue. Whatcha think?

[backwoodsboy]

Soot on the firewall is a pretty clear sign of the up-pipe to the turbo leaking. Add in the low boost numbers, and high EGT's and I'd put money on that being your problem.

[cweiss87]

^^^he said it. Up pipe leakin you lose some exhaust pressure to the turbo and you won't spin it all the way to build full boost.

[rplowden]

So, is there an o-ring or seal that I need? Or is it just a matter of tighteningthe clamp? I have the D66 turbo w/ downpipe. How difficult to replace that seal?

[rplowden]

Well, I went out to tighten down that clamp (which tightened up easily) and this is what I found...FML! Options? Don't wanna spend a fortune, but don't really want to downgrade either.

[backwoodsboy]

It's a little hard to tell from the pic, but from what I can see it looks like you've got a hole rusted through on the exhaust side of the turbo? Never seen that one before...
Generally its "just" a matter of replacing the gasket. This is still a huge PITA. In order to get enough room to work, you either have to remove the turbo or drop the transmission.
You can also replace the entire up-pipe with a bellowed one that eliminates the gasket, but that will cost you some serious coin.
Pipes:
OBS-E99 Bellowed Up-Pipes
Gasket:
Swamp's Webstore - 7.3L Up-pipe donut gaskets (1994-2003, 7.3L)

How old is that turbo? I see you're running a D66, so I assume it's relatively new.

[rplowden]

As far as the turbo goes, is that something that can be replaced? Like a housing, or do I need a complete replacement?

And is there any reason not to drive it like this as long as I keep an eye on the EGT's?

[351fifty]

you should be able to get a new exhaust housing for it, where did you get the d66 from anyway?, youve been doing it this long, but i would fix it asap if i were you

[rplowden]

Bought it like this. Everything was already installed, don't know how long ago though. The housing is pretty rusted, I'm afraid the bolts are just gonna snap off when I try to take the thing apart. I guess we'll find out.

[backwoodsboy]

Yeah finding a new exhaust housing shouldn't be too hard. They aren't typically a high fatigue item, so check out the local junk yard.
PB-Blaster is your friend. Heating/cooling cycles have a tendency to make any exhaust or turbo bolt fairly hard to get out.