Banks Power Ford Trucks: (Diesel ’99 - 03 7.3L Power Stroke) Power Systems- Big Hoss Bundles '99-03 F-250 & F-350 - Manual (Page 4)

Turbocharger
removal
8.
Remove the decorative plastic
cover directly over the engine.
9.
Loosen the clamp holding the
air intake hose at the turbocharger
compressor inlet. Pull the hose free
of the turbo compressor. disconnect
the boost line attached to the
nipple on the wastegate actuator.
disconnect wiring and plastic tubing
attached to components on the turbo
compressor discharge plenum casting.
10.
Loosen the four clamps on the
hoses connecting the compressor
discharge plenum casting to the
intake manifolds. Loosen the
clamp attaching the plenum to the
turbocharger compressor outlet and
the intercooler duct. Remove the
compressor discharge plenum from
the engine. cover the two intake-
manifold hose nipples with clean
rags to prevent foreign objects from
entering the engine.
11.
Disengage the exhaust-
backpressure control actuator rod by
sliding the cover on the end of the
rod back toward the turbocharger
and pulling the rod downward. This
rod is below the turbine housing;
it is not the wastegate actuator
rod that runs across the top of the
turbocharger (see Figure
3 ).
12.
At the rear of the turbine
housing, loosen and remove the
V-band clamp attaching the turbine
housing to the exhaust inlet casting.
Remove the two bolts attaching the
turbocharger bearing housing to
the pedestal base mounted on the
engine. Remove the turbocharger
from the engine by lifting while
lightly tapping the turbine housing
with a hammer.
13.
Remove the two O-rings from
the junction of the turbocharger
bearing housing and pedestal
mount. Place a clean rag over the oil
passages in the pedestal mount and
the exhaust inlet casting to prevent
foreign object entry.
14.
At the back side of the
turbocharger, locate the small e-clip
that retains the actuator rod end on
the wastegate arm. Using a small
screwdriver, carefully pry the clip off
of the wastegate arm and retain for
reuse. CauTIon: This clip is very
small and is easy to lose. It may
help to use a magnet to retain
the clip as you remove it. Loosen
the two wastegate actuator nuts on
the turbocharger compressor housing
and remove the actuator.
For vehicles with build dates in
1998 proceed to Step
19 .
15.
Remove the four bolts
securing the turbine housing to the
turbocharger center section. If the
turbocharger is more than a few
months old, it may be necessary
to spray some Liquid Wrench (or
similar rust penetrating lubricant)
into the joint between the turbine
housing and the center section.
Work the housing loose from the
center section by tapping with a
hammer and brass drift or a soft
face hammer. Work from side to
side and use plenty of lubricant until
the housing is loose from the center
section. Pull the housing straight
off of the center section to avoid
damaging the turbine blades.
Compressor wheel
Installation
16.
Remove the five bolts around
the outside of the compressor cover
and carefully remove the cover by
pulling it straight off the turbocharger
assembly, avoiding contact with the
compressor wheel. Use caution to
avoid damaging the sealing o-ring
around the outside diameter of the
compressor back plate.
17.
Secure the turbine wheel
in a vise by clamping the hub of
the turbine wheel. Remove the
compressor wheel using a
5 ⁄
8
” socket.
Install the new compressor wheel
provided in the kit. Slide the wheel
onto the shaft and lightly turn the
wheel to engage the threads. If the
wheel does not easily engage the
threads, back the wheel off and try
again. It may be helpful to listen for
a small click while rotating the wheel
counterclockwise, and then rotate
the wheel clockwise again. Once
the wheel has engaged the threads
properly, spin it on by hand until
snug. Using a torque wrench, tighten
the assembly to 100 in/lbs (not ft/lbs).
Reinstall the compressor cover,
making sure that the o-ring is
properly seated against the backplate
of the turbo. Reinstall the five bolts
and tighten.
18.
Place the turbine housing onto
the center section, again paying
careful attention to the turbine
blades. Apply some anti-seize to the
four bolts and reinstall them. check
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