The utility has been back into the dealers a few times now for a “Squealing” exhaust noise. The best way to describe the noise is as follows. As a child I used to drive my parents mad….. er hang on forgot were I was for a moment. Anyway as a child can you remember getting a blade of grass placing it between your thumbs and blowing The resulting noise is similar to the noise this vehicle produces when accelerating or crusing. Clearly there is an issue she has had 2 new turbo’s and 3 new turbo to manifold gaskets.
I have decided to take things into my own hands and have stripped the turbo from the engine. The first findings we noticed were soot deposits on the intake side of the turbo and mating flanges. When we removed the turbo (30miutes) we noticed that the triangular stainless steel gasket had a crack in it on one of the narrow widths. I am going to check that the mating surfaces are flat. If they are then I will fit a suitable higher standard gasket. As the tinfoil that Ford have specified is clearly not up to the job.


Zoom in to this pic (sorry Martin used full BBCode) to see soot deposits and where the gasses ware escaping from. Unfortunately you cant see in this picture the soot to the right of the yellow arrow as the turbo housing is in the way.

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Nice pictures Andrew these for sure will help other forum members,
have you refitted the turbo yet with a new gasket or a upgraded one ?

Give me a shout if you manage to locate a better replacement gasket id be very intrested in the final soloution you have come to.
Also let me know if you did actualy find if the mating faces were out of shape.




Regards Pete
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www.bellautoservices.co.uk/index.php

Pete

I have found a gasket supplier that has something suitable only thing is I have to pay for the tooling as the gaskets are tough little buggers and they will have to be pressed out.
I have not had chance to check the mating surfaces yet but hope to later. I will keep you informed

Found that the flange on the exhaust manifold had warped

Click image to enlarge

Thats a pain

At least you found the problem

better than landrover all they can do is fit new gaskets lol
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Been there got the T-shirt Andrew! On my 2nd Turbo now and they realised that when they fitted that they hadn't tightened it properly, otherwise they would have fitted a 3rd..... Were you towing when it started sqealing? All 3 times I have had problems I was towing, but (and I am touching wood) it has been fine for the last 2 months, picked up a new digger and trailer today and towed it 30 miles home with no issues, which is nice! Also towed an Ifor Williams with about 6 tonnes of spoil on it from one side of the site to the other (about 600 metres of mud and slopes) with no worrying noises so it's looking like mine is cured.
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2007 Defender 90 XS Station Wagon
2008 Disco 3 HSE
Audi A5 3.0L TDI Quattro - WOW
Volvo V70 D5 - GONE
1995 300 Tdi with lots of toys - GONE

Bogblaster wrote:

Were you towing when it started sqealing?

This is the turbo flange during machining.

Don't want to interfere Andrew, but I really think that you should have used something a little more refined than a Stihl chainsaw for your machining

I know your shed is an agricultural building, but come on!
_________________
2007 Defender 90 XS Station Wagon
2008 Disco 3 HSE
Audi A5 3.0L TDI Quattro - WOW
Volvo V70 D5 - GONE
1995 300 Tdi with lots of toys - GONE

Bogblaster wrote:

Don't want to interfere Andrew, but I really think that you should have used something a little more refined than a Stihl chainsaw for your machining

I know your shed is an agricultural building, but come on!