1978 Ford Sabre 150HP Turbo Problem

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cygnusv

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I did put this enquiry on 'Reader to Reader' but the first response I got was that I should repost here, as this is where I will find the right advice.

As you'll see from the pic's, the exhaust flange studs have all broken and the exhaust elbow fell off. My intention was to get hold of a service exchange unit but unfortunately (so far) this has not been possible. The price quoted for a complete rebuild was off the chart. Looking at the damage, I see an engineering job - re-drilling, tapping and new studs. I'd like views on this if possible.

Alternatively, if one is available, I would consider a fair priced exchange if anyone has old stock. The engine and turbo numbers are listed below.

Engine numbers

Serial 066172
Type 150

Numbers from the turbo plate

Header title 'Hoeset' or 'Holset' - 3rd character not clear
S/N 442799
Part number 55325/1
Engine num (looks like) 3L092.24

Exhaust Elbow.jpg-----Turbo Exhaust Flange.jpg

There appears to have been a spacer plate (about 5mm thick) seperating the exhaust flange from the elbow, I've not tried to seperate it from the elbow yet. Also, when I removed the elbow there as a rotten clamp there too. I need to identify a replacement for this.

So then, any ideas?

Apologies again for the apparent double post.

Many thanks, Stu
 
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Definitely a Holset, we used to " spark erode" the studs when we had this problem. Mind you this was at Ford R& D so all equipment was available ! If memory serves the studs were stainless.
 
essexboy said:
Definitely a Holset, we used to " spark erode" the studs when we had this problem. Mind you this was at Ford R& D so all equipment was available ! If memory serves the studs were stainless.
Click to expand...

The studs don't actually look like stainless steel. Out of interest I mentioned a seperator plate. Am I right? and was this held in place with flush fitting screws?
 
I had a similar problem with a holset turbo on a ford mermaid 180 6 cylinder. I had to replace the exhaust elbow as it was leaking. Every stud snapped off when I tried to take it apart.
Have a really good look at the exhaust elbow whilst its off. Assuming both parts are sound excepting the studs, take it to a local engineering workshop and get them to skim the turbo exhaust flange surface to get it flat (else it won't seal exhaust gases). Then drill and tap new stud or bolt holes offset from the originals. If you have the skill and patience you could do it with a decent file and a hand drill etc, but you will only get one chance when drilling new holes.
It looks like someone has done exactly this before. I am not sure drilling out the old studs and helicoiling will work as the air cooled turbo gets seriously hot.
I think the turbo exhaust casting is cast iron so I don't think you can reliably or easily weld up the old holes and re drill them.
 
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Those broken off studs can be redrilled, centre punch then start a small drill bit and gradually open up, if your really lucky the thread will still be there, ours was. Re the clamp readily available on ebay, 3.5" if I recall, could be 4" and yes there is a gasket between the snail and the elbow. Have you got the back end of the manifold ready to accept the snail? When you remove the rusted clamp you will find there are two faces, one bolts to the snail (with new bolts, not stainless) and the other should be on the exhaust elbow, yours looks like it has rusted off. The problem lies with not examining behind the shield/lagging, and as stated with the heat generated and water leaks rust gets a good hold in a very short time. Relax all is not lost. You may find that the elbow will be held with a clamp to the snail.
https://postimg.org/image/57a3pfour/
this is a straight bolt on, others are in two pieces, one bolts to the snail and the other is on the elbow and a clamp holds them together.
 
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So am I right to believe that there is a spacer plate separating the snail from elbow, and that this IS fastened to the snail with flush faced screws? Are the studs that affix the elbow stainless as has been mentioned? And how would I describe the clamps on eBay?
I must say that this is VERY helpful
 
cygnusv said:
So am I right to believe that there is a spacer plate separating the snail from elbow, and that this IS fastened to the snail with flush faced screws? Are the studs that affix the elbow stainless as has been mentioned? And how would I describe the clamps on eBay?
I must say that this is VERY helpful
Click to expand...

Turbo clamps lots on ebay, Re the gasket, the snail is fitted with studs and the gasket slides onto them, the elbow is then offered up and bolted, We gave the faces a good coating of fire clay (gum gum) before fitting. Old fashioned belt and braces. Let me know when you have removed the rusty clamp.
 
Also those marks on the snail that appear to be blind holes, they are not! they are created by the flange which as you will find has several holes for mounting on different jobs. Do not drill them they will not line up anyway. Work the old holes. iirc the studs are 1/2" AF. most hardware shops should have them? if you can find such a place these days.
 
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