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Old 02-09-2008, 11:06 AM   #128
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Join Date: Sep 2004
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Location: Fairmont, WV
What I Drive: 06 Sonic Blue ZX5 SES turbo

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Just an update.
After 5k miles my original turbo died and oil blew past the seals and into the exhaust.
I was only 1/2 mile from home so there were no adverse side effects.
I rebuilt the 2nd turbo I had using a kit from and it's working great.
I feared part of the issue was over-oiling, so I installed a .06" oil restrictor and am now running 5w30 oil.
It gets very cold here, and my oil pressure was very high with the 10w30 oil.

Here's a couple new pictures:

Burned oil on the exhaust side of the turbo:

Rebuild kit:
The Tbird IHI uses the Narrow bearings, not the wide.

I made my wastegate actuator rod adjustable:

The first turbo I installed had cracks around the WG port.
The freshly rebuilt turbo has no cracks!

Lessons learned:
- When going with a used turbo, go ahead and rebuild it just to be safe.
- Use an oil line restrictor when your oil return line exists at or below the oil level in your oil pan.
- Don't preload your WGA too much. It increases boost. 1/4" preload put me at 11psi. Higher than I wanted for now. (I'm at 9.5psi)
- When using band-style exhaust clamps, tighten with an impact wrench. I could never get them tight enough by hand and they always leaked.
- 2" IC piping would have been sufficient. 2.5" has caused more clearance headaches than anything.
- Use T-bolt style clamps. I used these from the beginning and they've been great.
- If you live in a hilly area, make sure your tuner provides enough fuel for part-throttle boost.
No I didn't have any issues, but sometimes I'd like it to be a tad richer.
- Use a Exhaust Gas Temp gauge if you can afford one. I don't have one yet.
- Budget for a new, stronger clutch from the start. The stock one WILL slip at 9.5psi of boost.
- Always be nice to your wife, just in case you blow off an IC pipe and you need her to bring you tools.
'04 Mach 1. Built. Turbo. 667whp/631wtq
'06 Focus. Built. Turbo. WMI. (sold)
'03 Mach 1 : 12.61 @ 106.59 (sold)
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