A little more history on this order....
He purchased a turbo rebuild from us back in Jan '07. Our records do not indicate that he purchased a .63 A/R turbine housing but I would have to research that more to confirm.
When he sent in his turbo for repair a few months ago the turbine wheel had sheared off and had bounced around so violently in the turbine housing that there was significant damage to the turbine wheel contour (See photo examples. Photos NOT of actual customer housing). The turbine wheel was actually jammed in the turbine housing so badly that a pry bar was necessary to remove it. After a full inspection we determined the failure was most likely due to oil starvation. The Turbonetics .63 A/R turbine housings are discontinued so we did not have alot of options to continue using it other then to move to a Stage 2 wheel. But, even after machining for the larger wheel there was still significant contour damage and we recommended a thin sleeve as a solution. Because of the larger turbine wheel in the .63 A/R we had to move to a larger compressor wheel otherwise there would not be enough airflow to drive the Stage 2.
The turbo was completed and sent to the customer. He contacted us within a few days of installing it and complained of excessive smoking. I asked him to check for turbine shaft play and he responded that there was none. We told him the smoke could be from residual oil left in the exhaust system from the previous turbo failure and to continue running the engine to see if it goes away. He said the smoke did clear up for a while but would reappear after extended idling. He said there was significant oil in the intercooler and we told him it may also be from the previous turbo failure. We suggested that he flush the intercooler and try running the engine with the PCV system disconnected for a while. We recommended that he also go through our "smoking turbo" checklist we posted in the knowledge center.
We asked him to check a few things including the spark plugs for signs of oil which he admittedly had not done yet. Based on all our future conversations with him we are unsure that he actually went through anything from the check list. He suddenly became more focused on accusing us of switching his turbo then solving the problem at hand. He also sent the attached pictures of the turbine housing and compressor cover accusing us of stealing his (see attached photos). I explained to him that we grabbed a clean compressor cover out of our stock and machined it for the new compressor wheel and that they are all the same internally. We were just trying to expedite his build along by not cleaning his original housing. He emailed us yesterday morning and said that he had contacted his CC company and had the charges reversed for the order (turbo, 3" SV, DP, etc. etc. =$1200+). He wanted us to send him another turbo for free and he would allow the CC charge to go through, then we would have to pay to have the first turbo returned to us. This is impossible because we don't have another .63 A/R turbine housing to build what he wants. He needs to send us his turbo back so we can properly evaluate it to see if there is anything even wrong. If the shaft is tight then it's probably something else causing the issue but we feel he has been reluctant to follow through with diagnosing the problem so a solution can be found.
The reason we posted this on T-M was because he emailed us this:
"Chris, so far it's just between me and you. If you want I can post the pictures on turbododge.com and see what they have to say about the housings."
I told him don't bother, I wouldn't even go to TD.com to read it. I then decided to post it on T-M instead.
Chris-TU
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Originally Posted by Juggy
