6.4 Turbo Removal Cab On - Ford Powerstroke Diesel Forum
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Old 06-12-2013, 11:32 AM
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6.4 Turbo Removal Cab On

I had looked online for a good write up on how to do this process and couldnt find any in detail. I blew the oil seal out of the vgt turbo and got a whole new assembly. So I will post up my way. I didnt use a lift or any special tools. Just a good set of sockets in 1/4 3/8 and 1/2 with multiple extensions(Feel free to add if you feel there is an easier way to do something good help is hard to come by these days and I am going off by memory so I may have left something out). And having a topside creeper would help but I didn't use one.

1. Remove negative side from batteries.(Or remove Batteries completely for parts and tool trays)

2. Remove intake assembly from filter housing to turbo. Be sure to unhook any sensors in your intake and make sure wire harness is out of the way from being ripped.

3. Disconnect fuel cooler lines and fuel lines to the cooler and fuel lines to the cooler. Remove cooler, reservoir, and turbo u-pipe. All can come off by un bolting from valve cover.

4. Disconnect oil feed lines to turbos and downpipe from turbo and exhaust and the CAC pipe to the turbo.

5. Remove two 10mm bolts from egr pipe to passenger side up pipe. Use lots of PB Blaster and heat and a good socket. Then remove two 10mm bolts from egr pipe to bracket on back of the turbos. Then wedge a block of wood between pipe and valve cover to hold it against the fire wall (I have the egr system removed from my truck, not sure if you will have the same amount of play with the egr pipe with the cooler still attached or not)

6. Remove the three 10mm bolts on the drivers side up pipe to the back side of the turbo. There is a bracket that will come off with the the top two bolts for the egr pipe. Kind of a pain to do but once broken loose a flex head gearwrench works wonders back there.

7. Remove cab mounting bolts on Drivers side and loosen passenger side. and jack up drivers side of the cab.

8. Remove three 13mm bolts from up pipe to manifold and pull out manifold then lower the cab back down.

9. Now with the drivers side up pipe removed the passenger side pipe will be a lot easier to access. Remove the 3 10mm bolts on the back of turbo to the up pipe.

10. Remove two 15mm bolts that hold the turbo and clamps to the motor.

11. Jack the cab back up on the drivers side and grab a buddy to help lift the turbos up and out. Be careful when removing and the drain lines at the bottom of the turbo can get caught up so lift strain up until you clear them. Then muscle it out.

12. Repeat in reverse order to re-install.

If anyone caught anything I missed or forgot please add. Not a hard process just somewhat time consuming. Hope this helps.
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Old 08-13-2013, 08:35 AM
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did you lift the cab because you didn't remove anything else around the turbo's?

I'm trying to replace head gaskets, getting started on pulling parts off top of the engine, thought I could this without lifting cab.
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Old 08-13-2013, 08:52 AM
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I did this to get clearance between the cowl of the cab and the turbos to be able to remove them. Not sure if this way will give you enough clearance to remove the heads or not depending if you have head bolts or head studs.
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Old 08-13-2013, 09:10 AM
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hmm, I was hoping there was enough room to lift the turbos off the intake/engine and pull them forward. There's basically nothing left on the top of the engine.

Guess, I'll find out in short order whether I need to lift the cab.

Head studs are on the agenda (as well as 'o-ringed' heads)...
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Old 08-13-2013, 12:29 PM
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Quote:
Originally Posted by ytudrepus View Post
hmm, I was hoping there was enough room to lift the turbos off the intake/engine and pull them forward. There's basically nothing left on the top of the engine.

Guess, I'll find out in short order whether I need to lift the cab.

Head studs are on the agenda (as well as 'o-ringed' heads)...
Looks like you could use this, it's a body on engine removal procedure, I don't think you need to pull the engine completely out but it's a good guide line on what components you need to get out of the way. Hope it helps

http://www.aev.com/uploads/file/BodyOn64EngineMtnc.pdf
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Old 09-22-2013, 12:58 PM
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Hey, just a quick note to close out my comment/question.
Completed my Head Gasket R&R (o-ringed the heads also), I got everything off (and back together) without lifting the cab, removing drive shafts, or the tranny. The only part that was a challenge are the turbo inlet pipes (big surprise there - right). Followed the procedures from the DIY Alldata - all is well, no leaks. Took some doing to bleed the air from the fuel system (drained the batteries cranking - twice).

2008 F250, Crew Cab, short bed.
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Old 10-27-2014, 09:58 AM
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Does anyone know about how high to jack the divers side of the cab up?
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Old 10-27-2014, 02:20 PM
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If your asking this related to pulling the Turbo's I did mine without touching the cab (did Drivers up-pipes, head, and all associated piece parts). I rented the special tool from the local dealer, after giving a good look and taking measurements I made my own (cuz DA showed up and I had to pull the turbo again...) ~ worked perfectly with engine hoist.

Without the tool, hmm that'll be tricky, I imagine you'll need two people.

Hardest part of the job for me was loosening those turbo inlet bolts in the back (my XXXL hands just had a hard time fitting), I bought new bolts and ran a tap through the holes to ensure an "easy" start (like typing with boxing gloves...).

Last edited by ytudrepus; 10-27-2014 at 02:25 PM.
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Old 10-27-2014, 04:04 PM
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Thanks...

Project was a fail... truck in pieces. Roll-back coming to get it in the morning. Local dealer won't work on a modded truck, so it has to go almost an hour away. When will I learn...?
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Old 10-28-2014, 03:53 AM
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Yea that sucks, sorry to here that. Too bad your not closer to central Penn (or me closer to you) I'd been glad to give a hand. Hope it works out, if you find them to be a reputable shop let others know.

Good luck,
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6.4 bad turbo, cab on, oil in exhaust, turbo removal

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