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Ford 7.3 Powerstroke Premium rebuilding services, Ford F-250 and F-350 Superduty trucks

WORK Turbochargers is proud to offer premium turbocharger rebuilding services for the 1994.5-2003 Ford Powerstroke 7.3 diesel engines found in the F-250 and F-350 Series Super Duty trucks. Every turbocharger rebuild will receive a full diagnosis of failure along with a consultation with you to ensure a thourough and successful rebuild experience.  Utilizing the very best in materials and labor, your turbocharger gets the same attention to detail that sets us apart from the ordinary rebuilding shop.  Full 3 stage balancing, blue printed oil circuits, highest quality bearings and seals and a full clean room assembly area  guarantee the very best turbo for your truck.  All of our rebuilds also include a full 2 year warranty as well as full technical support to help you along the way.


WORK Turbochargers Premium Rebuild: Recommended for Powerstroke trucks utilizing high performance computer, air filter and exhaust upgrades.  If you are interested in an upgraded high performance turbocharger for you modified Ford, please visit our upgrade page for details!

  • All parts fully cleaned and inspected
  • 3 Stage balancing of the rotating assembly
  • Turbine shaft OD machined for new bearing surface
  • Bearing housing journals bored and honed
  • New 360* thrust bearing and collar fitted for durability
  • High temperature compressor seal upgrade fitted
  • New backplate installed
  • Bearing housing coated in high temp corrosion resistant black finish
  • Compressor housing coated semi gloss black corrosion resistant finish
  • Wastegate actuator calibrated (1999 and newer)
  • Turbine inlet sealing surfaced (1998 and prior)
  • All turbochargers are assembled in a clean room environment
  • 2 year warranty
  • Price $675.00 + shipping for a rebuildable core
  • Core charge $300.00, please see core information in 7.3L Rebuild FAQ

Work Turbochargers also understands the value of today’s dollar, with that in mind we offer our standard rebuilding service for the Ford Powerstroke. Every rebuild includes fitting your existing backplate with an oversize seal ring and also utilizing the OEM 270* thrust bearing for general purpose applications.  If your Powerstroke is in need of a high quality OEM rebuild, we would be happy to help! 

  • All parts fully cleaned and inspected
  • 3 Stage balancing of the rotating assembly
  • All clerances are blue printed
  • New thrust bearing and collar
  • New seals and gaskets
  • Bearing housing coated in high temp corrosion resistant black finish
  • Compressor housing coated semi gloss black corrosion resistant finish
  • Wastegate actuator calibrated (1999 and newer)
  • Turbine inlet sealing surfaced (1998 and prior)
  • All turbochargers are assembled in a clean room environment
  • 2 year warranty
  • Price $450.00 + shipping for a rebuildable core
  • Core charge $300.00, please see core information in 7.3L Rebuild FAQ

 

What determines if your Powerstroke turbocharger is rebuidable?

  • In most cases, the easiest way to determine if your turbocharger is in rebuildable condition can be accomplished with a simple visual inspection. The first thing you want to do is look at the condition of the compressor (intake) wheel and check for evidence that it has rubbed or touched the compressor housing. Most turbochargers that we see without any contact directly between the housing and wheel can be classified as rebuildable. If you have experienced engine failure, water in the oil, cold start valve malfunctions or other major engine related problems your turbocharger could have issues that are non repairable even though there has been no contact damage to the compressor wheel. Prior to shipping your turbocharger to us for service, we will go over a thorough list of questions to gain insight to the cause of your turbocharger problems.

Why does WORK Turbochargers recommend to rebuild my original 7.3 Powerstroke turbocharger?

  • The reason we want to rebuild the turbo off of your truck is simply to give you all the information regarding the cause of failure, or condition of your turbocharger. For example, let us assume your turbo has problems due to a high pressure coupler leak allowing over speed damage to occur, this may go un diagnosed. Installing the new turbocharger without any knowledge of the underlying problem will immediately damage your new turbocharger. We will fully evaluate your turbochargers condition and a full consultation will be provided to you allowing your newly rebuilt turbocharger to perform properly for many years.

My Powerstroke turbocharger has been upgraded, can WORK Turbochargers still service my unit?

  • WORK Turbochargers will be happy to help wherever possible, but some upgraded units have either mis matched component parts, incorrect machine work and other problems. You will be required to send in your turbocharger in order to receive a quote for rebuilding. There is a $35.00 service charge to inspect the turbocharger and provide a rebuild quote. If you choose to have the turbocharger rebuilt by us at that time, the $35.00 fee will be credited to your original quote. Please feel free to contact us with any questions.

My 7.3 Powerstroke has an aftermarket Borg Warner turbocharger, can it still be rebuilt?

  • WORK Turbochargers carries a full line of service parts for the Borg Warner TP-38 replacement turbocharger for the 7.3 Powerstroke. Pricing, warranty and turn around time are the same as the Garrett unit originally installed on your truck. Contact us directly with any questions or concerns, we will be happy to help you out.

Does WORK Turbochargers offer new outright Powerstroke turbochargers?

  • Yes! WORK Turbochargers carries a full line of new Garrett and BorgWarner replacement turbochargers for the F-250 and F-350 Powerstroke turbo diesel covering all years of production. Please contact one of our turbocharger specialists today with your needs.

Does WORK Turbochargers offer high performance or upgrade parts for my 7.3 Powerstroke turbocharger?

  • Yes, we offer upgraded exhaust housings, compressor wheels, waste gate actuators as well as complete new high performance turbochargers. Please visit our high performance page for details!

What is the turn around time to rebuild my 7.3 Ford Powerstroke turbocharger?

  • We are a very small specialized shop, so turn around time is very fast. For a fully rebuildable turbocharger you will be looking at 2-5 business days plus the shipping time. WORK Turbochargers also offers same day turn around by appointment on all years of the 7.3 Powerstroke Ford turbo, please contact us for an appointment and quote.

Why is there a core charge?

  • If you are not sending your turbocharger in for rebuild, and would like to purchase a unit out right there will be a $300.00 core charge applied to the base price. If you choose to send your core in afterwards you account will be credited up to $300.00 depending on the condition of your turbocharger core. If your turbocharger core is in perfect rebuildable condition you will receive a full $300.00 credit back to your account. If the core is damaged due to oil contamination, bearing failure, overspeeding, foreign object damage, it's value will be adjusted accordingly.
  • If you are sending your turbocharger in for rebuilding service, there will be no core charge applied.

Why do we coat the compressor housing with a corrosion resistant paint?

  • The TP-38 Garrett turbocharger found on the 7.3 Ford Powerstroke incorporates a precision die cast compressor housing that is made of 2 parts. These parts have voids, or recesses, that will trap a large amount of oil over the turbochargers lifetime. This oil is impossible to fully remove from the housing during cleaning. Most standard turbocharger shops will sandblast this housing, greatly increasing the risk of the engine ingesting blasting media causing engine damage. We choose to hot tank wash our housings, and to make them reach our high standards for appearance we choose to apply a satin black coating that matches many factory underhood accessories. As an added bonus, this coating is salt resistant, helping control under hood corrosion in winter driving conditions where the roadways are salted for safety. The coating also has a thermal barrier property that helps keep under hood heat out of the turbocharger, increasing horsepower and bearing life. 

 

 

The Ford 7.3 L engine has received a few different turbocharger models during its production years.  All of the units found on the 7.3 are based around the Garrett TP-38 family of reverse rotation turbochargers.  Starting mid year 1994 and carrying over to 1997 models, the first generation TP38 turbocharger features a non wastegated 1.15 A/R turbine housing. From 1998-to mid year 1999 a wastegated version was available to enhance boost response.  Starting in 1999.5 the compressor wheel and housing were updated, carrying through the rest of the 7.3 Powerstroke’s production run.


What is the turbocharger model on my 7.3 Powerstroke Ford truck?

  • Your trucks original equipment turbocharger is a Garrett TP-38 unit.  It was designed for use on all Powerstroke and also International/Navistar T444E diesel engines.  Over the production years of the 7.3 liter engine there have been some small changes to the design of this turbocharger, including 2 different compressor housings, compressor wheels, turbine housings and turbine wheels.  The engine’s year model and application determine the correct Powerstroke turbo unit for your truck.

How to identify the Garrett TP-38 turbo on your 1994.5-2003 Ford 7.3 Powerstroke engine

  • When you contact us for rebuilding information on your turbocharger, we will simply need to know if your truck is an F-250/F-250 HD, F-350, Van or commercial F-450.  We will also need the year model, transmission type and if it is 2WD or 4WD.  You can also provide the ID tag information found on the compressor housing or back plate of your OEM turbocharger.

 

Common causes of turbocharger failure in the 7.3 Powerstoke Ford, F-250 and F-350 trucks

Oil consumption from faulty compressor or turbine seals on the Garrett TP-38 Powerstroke turbocharger

  • This occurs mainly from normal wear and age, the turbine side piston ring in the OEM turbocharger looses its ability to accurately seal against oil entering the turbine housing and causing white-grey smoke once the truck has fully warmed up. The compressor side seal fails in the same way, allowing oil to enter the intake manifold and producing grey-blue smoke when the truck is started, or even when pulling away from a stop. Both of these seals are replaced in our rebuild, and the areas of the turbocharger that they seal against are replaced or re-machined.

External oil leaking on 1994-2003 7.3 Ford Powerstroke turbochargers

  • There are three things we commonly see that cause oil leaks around the turbocharger. First is simply the oring seals between the mounting pedestal and the turbocharger bearing housing. Installation of new oring seals will correct this problem when the rebuilt turbocharger is re-installed. Second is a cracked bearing housing. Most of the bearing housing cracks will occur between the lower bearing housing to exhaust housing bolts, the oil leak will appear to originate from the head of these bolts. Cracked bearing housings must be replaced when the turbocharger is rebuilt. Cracking is most common in the non wastegated applications from 1994.5-1997. The last problem area is the backplate to compressor housing bolts coming loose and allowing oil to pass by the bearing housing quad ring. This is caused by vibration or incorrectly torqued hardware during rebuilding. This failure is usually detrimental to the turbocharger, leaving it in a non rebuildable condition.

Thrust bearing failure on the Garrett TP-38 series turbocharger

  • Failures of this nature can usually be traced back to over speeding due to an pressure coupler leak, broken intercooler end tank if equipped, improper computer programming with more than 35 psi of manifold pressure, improper cool down prior to shutting off the vehicle, improper cold start valve function or improper oil quality or service interval. It is important to measure axial movement on your turbocharger at every oil change. Total indicator movement must not exceed .004” for a healthy turbocharger. If the bearing is allowed more clereance, there is a greater chance of compressor wheel damage due to contact with the housing at high speeds, rendering the turbocharger non serviceable. Our premium rebuilding service addresses the standard OEM thrust bearing assembly, replacing it with a much improved 360* billet bearing capable of withstanding higher thrust loads for performance applications.

Journal Bearing Failure on the Garrett TP-38 series turbocharger

  • Damage to the journal bearings inside the Garrett TP-38 turbocharger usually is the result of oil contaminates, improper oil service or quality, improper shut down or just normal wear over time. The journal bearings locate the turbine shaft assembly radially within the bearing housing, and under full load these bearings contain this shaft at speeds approaching 100,000 RPM. During our rebuilding process, the surface of the turbine shaft as well as the bearing housing will be machined to a strict tolerance that allows the turbocharger to perform properly.
  • Picture show is of a new journal bearing (left), and a damaged journal bearing due to oil contaminates (right)

Compressor wheel damage on the Garrett TP-38 Powerstroke turbocharger

  • Damage to the compressor wheel is commonly the result of a foreign object entering the turbocharger through an air filter fault or a loose connection. It is very important to maintain the air filter and hose assembly on your F-250/350 Powerstroke truck in order to prevent damage to the delicate compressor wheel. Anytime the air filter is serviced, care must be taken to keep stray leaves, pine straw, dirt and debris from entering the air filter pipe assembly. The turbocharger spins over 100,000 RPM, any debris will damage the compressor wheel and cause imbalance issues, drastically shortening the life of the turbocharger.

Turbine wheel damage on the Garrett TP-38 Powerstroke turbocharger

  • The turbine wheel can be damaged due to over heating and also foreign object damage. Over heating usually is the result of over fueling or a restricted exhaust. The turbine wheel is subjected to very high temperatures, and due to the design of the wheel and housing damage can occur quickly if left un diagnosed. Any 7.3 Powerstroke truck that has been modified with a performance computer program, air filter system or exhaust will need to install an exhaust temperature gauge, or pyrometer. Consequently, incorrect installation of the thermocouple probe can also create debris in the exhaust system that can damage the turbocharger. Do not operate your truck if it is experiencing excessive black smoke and a noticeable lack of power, immediate turbocharger or engine damage will result.
  • The turbine wheel pictured shows damage to blades

Cold start valve malfunctions on the 7.3 Ford Powerstroke

  • All the Ford Powerstroke turbochargers are equipped with a simple exhaust shut off valve on the outlet of the turbochargers exhaust housing. This valve is actuated by a thermostatically controlled oil actuator to provide a restriction in the exhaust system allowing the engine to warm up faster in cold climates. This valve is very sensitive to both oil pressure and viscosity, using the incorrect oil will usually result in a valve malfunction at some point in the turbochargers life. Symptoms will be extreme lack of power, water temperature over heating when the engine is operated above idle RPM, noticeable deacrease in exhaust sound, inability for the engine to accelerate and possibly a different smell coming from the engine compartment due to the heat build up under the hood. The actuator valve is located in the turbochargers pedestal stand, or spider. Usually they are in serviceable condition and can be rebuilt, however if there is excessive damage to the actuator, the entire pedestal must be replaced.

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