Exhaust Leak - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 10 (permalink) Old 06-18-2014, 04:19 AM Thread Starter
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Exhaust Leak

Howdy All,
So I have an exhaust leak.
A few weeks ago I tore out my exhaust and up pipes, everything. Looking at the y-pipe and everything else, I found the exhaust leak to be coming from where the down-pipe meets the turbo.

The turbo is in great condition except for the mating surface of the down-pipe it is heavily pitted. I thought I ground it down smooth, but my leak persists.

My question is: does anyone know of anything that I can use as a sealant or a gasket to put there?
The highest temp RTV i can find is 600 F. there are some exhaust tapes I've found, but they say they make a permanent bond (and we all know the turbo can come off quite a bit).

Any ideas are greatly appreciated!

2004 (09/2003 build, call it an 03) F250 XLT 6.0 CCLB:
ARP Studs | Turbo back 4" MBRP | MBRP cat "test" pipe | XDP EGR delete | blue spring | upgraded turbo oil drain | homemade Baldwin coolant filter kit | Fumoto oil drain (F-111) and block coolant drain (F-108N) valves | SGII | EGT/Fuel Pres/Boost 3-in-1 Glowshift | Cold a/c mod.

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post #2 of 10 (permalink) Old 06-18-2014, 05:06 AM
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So the downpipe is pitted or the flange on the turbo outlet?

If it's the downpipe, replacement would be best.

If it's the turbo flange, you could try something like this or similar...
http://www.aremco.com/news-item/pyro...-metal-sealer/

Harry

Jan 03' built 6.0/F250cc4wd trqsft/SCT-tuned by KEM-Performance/Garrett Powermax vg-turbo/blue spring mod/gauges=egt+boost+fuel+SG2/exhaust/airaid intake/DR 4.5 lift/dual bilsteins/315's/greasable ball joints/powerstop/smittybuilt/kc lights/high idle mod/roll-n-lock/Mobil Delvac1 ESP 5W40 with (Archoil AR9100 in the oil) and (AR6200 in the fuel)
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Rellick (06-19-2014)
post #3 of 10 (permalink) Old 06-18-2014, 05:24 AM Thread Starter
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It is the turbo flange.
I saw that stuff.
I was kind of hoping on something that would be easier to do in place (without making a permanent seal), but that would probably work if I pulled the turbo. Hmm...

Once again, Thank you Harry!

2004 (09/2003 build, call it an 03) F250 XLT 6.0 CCLB:
ARP Studs | Turbo back 4" MBRP | MBRP cat "test" pipe | XDP EGR delete | blue spring | upgraded turbo oil drain | homemade Baldwin coolant filter kit | Fumoto oil drain (F-111) and block coolant drain (F-108N) valves | SGII | EGT/Fuel Pres/Boost 3-in-1 Glowshift | Cold a/c mod.

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post #4 of 10 (permalink) Old 06-18-2014, 02:09 PM
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Might be able to just use some JB-Weld applied to the turbo flange, let it dry and sand it smooth so just the pits are filled in. When you said...I thought I ground it down smooth...hopefully no metal was ground away to where the sealing surface is not flush or wavey. A new v-band clamp can do wonders too if the old one is tweaked or bent in any way.

Harry

Jan 03' built 6.0/F250cc4wd trqsft/SCT-tuned by KEM-Performance/Garrett Powermax vg-turbo/blue spring mod/gauges=egt+boost+fuel+SG2/exhaust/airaid intake/DR 4.5 lift/dual bilsteins/315's/greasable ball joints/powerstop/smittybuilt/kc lights/high idle mod/roll-n-lock/Mobil Delvac1 ESP 5W40 with (Archoil AR9100 in the oil) and (AR6200 in the fuel)
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post #5 of 10 (permalink) Old 06-18-2014, 05:12 PM Thread Starter
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We were pretty conservative and even when grinding, just trying to get all the pits off.

The issue I saw with JB weld was that it it only goes up to 400-500 F. being that it would just be a little to smooth it out, that might work too.

I had thought of using some exhaust gasket material and sandwiching it in with some of the 600 F copper RTV from permatex.

2004 (09/2003 build, call it an 03) F250 XLT 6.0 CCLB:
ARP Studs | Turbo back 4" MBRP | MBRP cat "test" pipe | XDP EGR delete | blue spring | upgraded turbo oil drain | homemade Baldwin coolant filter kit | Fumoto oil drain (F-111) and block coolant drain (F-108N) valves | SGII | EGT/Fuel Pres/Boost 3-in-1 Glowshift | Cold a/c mod.

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post #6 of 10 (permalink) Old 06-18-2014, 06:07 PM
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And you're sure it's the downpipe and not the turbine inlet at the Y of the up pipes? The turbine inlet to y-pipe is the hardest thing to align and properly seat, and if you had everything apart, I'd start it cold and give that connection a quick feel for leaks. This would be the first time in ten years I've seen someone post that the V-band connection on the downpipe is the source of the leak.

The Current Truck (Oct-2013 to Present):
1999 (Early) F-350 Lariat, CCLB, SRW, Black/Tan

7.3L Powerstroke, 4R100, 4x4, 3.73, 37x13.50-18s, '05 Axle Swap, 6" Fabtech lift, GTP38 "D66" turbo upgrade, SCT 4-position chip with custom tuning by me, Straight Piped 4" down pipe through 5" dual stacks, N-Fab full length triple steps, Pro-Tech cab guard and tool box, louvered 5th wheel gate, Hella 500 Fog and Driving lamps, much more to come...
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2000 Excursion XLT 4x4

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Last edited by IdahoF350; 06-18-2014 at 06:12 PM.
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post #7 of 10 (permalink) Old 06-18-2014, 06:16 PM Thread Starter
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Yes sir, even soot inside of the clamp.
When I pulled all of it off, the y-pipe had no soot anywhere and I put on the inlet clamp before I tightened 'em back to the exh manis. I also replaced the pass up-pipe with a straight pipe (egr delete).

2004 (09/2003 build, call it an 03) F250 XLT 6.0 CCLB:
ARP Studs | Turbo back 4" MBRP | MBRP cat "test" pipe | XDP EGR delete | blue spring | upgraded turbo oil drain | homemade Baldwin coolant filter kit | Fumoto oil drain (F-111) and block coolant drain (F-108N) valves | SGII | EGT/Fuel Pres/Boost 3-in-1 Glowshift | Cold a/c mod.

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post #8 of 10 (permalink) Old 06-19-2014, 06:22 AM Thread Starter
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I talked to a machinist today, he actually recommended pyro putty. Said he's seen guys put holes in turbos and fix it with the stuff. Hot side even. I guess I'll go that route at some point and just do it real thin and even. Wish me luck!!!

2004 (09/2003 build, call it an 03) F250 XLT 6.0 CCLB:
ARP Studs | Turbo back 4" MBRP | MBRP cat "test" pipe | XDP EGR delete | blue spring | upgraded turbo oil drain | homemade Baldwin coolant filter kit | Fumoto oil drain (F-111) and block coolant drain (F-108N) valves | SGII | EGT/Fuel Pres/Boost 3-in-1 Glowshift | Cold a/c mod.

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post #9 of 10 (permalink) Old 06-25-2014, 12:49 AM
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I am surprised no one makes a copper seal for those turbo flanges. I've installed many turbos that were pitted but none leaked.
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post #10 of 10 (permalink) Old 06-25-2014, 02:23 AM Thread Starter
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I tried to make a copper gasket, but it wouldn't lay flat. I must be lucky. I've been that way with this truck. =) I found some 2000 silicone type stuff that I'm going to try when I get a chance to dig in there. I'm going to test it on a couple pieces of metal first just to see how permanent it might be.
http://www.amazon.com/gp/aw/d/B000BK...&robot_redir=1

2004 (09/2003 build, call it an 03) F250 XLT 6.0 CCLB:
ARP Studs | Turbo back 4" MBRP | MBRP cat "test" pipe | XDP EGR delete | blue spring | upgraded turbo oil drain | homemade Baldwin coolant filter kit | Fumoto oil drain (F-111) and block coolant drain (F-108N) valves | SGII | EGT/Fuel Pres/Boost 3-in-1 Glowshift | Cold a/c mod.

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