chip66
Registered User
Apparently, people have been struggling with this job for decades now.
I'm a few months into my first Powerstroke with a '97 crew-cab dually.
When I purchased it, I knew it was leaking from the up-pipes pretty badly. After watching many YouTubers explain the challenges of removing the turbo, I purchased a few tools and parts and went to work this weekend. I spent most of Saturday working on the two lower nuts, broke my flex socket, and returned to the drawing board. I watched several more YouTubers, all had the same flex socket "solution." Frankly, that's a crap solution, but with tools available on the market may be the best you can buy.
Instead of buying another flex socket, I made a tool to fit the workspace. Excuse the crappy welding from the $80 Harbor-Freight flux core:
This was my second try after using a socket and wrench from Menard's. It failed to hold on to the nut. 1/2" drive also had clearance problems on the driver's side.
After the Menards house brand failed, I watched a couple of Torque Test Channel videos to find a good boxed-in 12pt wrench. The Craftsman tested really good, and Lowes had the 15mm in stock. (I wasn't about to cut my USA-made Craftsman wrench). Using wrenches on the shelf, I found that a 16mm would fit over it. They didn't have a 3/8" drive 16mm 6pt impact socket, so I bought a chrome one.
I cut the socket open to two opposing edges and welded the wrench in to allow 1 1/4" clearance. I cut the wrench off and rounded it back off on the grinder.
1st, hit with my impact, and the nut turned. A few minutes later, I had both sides off.
Here are a few other pictures of the home-made tool:
It took me about 30 minutes to make version 1 and about 15 minutes to make version 2. Had I seen this information elsewhere, this is where I would have started.
If you decide to make one of these, be sure to grind off the chrome or zinc plating before welding. You don't want the toxic fumes that will be produced.
I hope this helps someone else looking to do this job.
I will duplicate this post on other forums where OBS Powerstroke people roam.
I'm a few months into my first Powerstroke with a '97 crew-cab dually.
When I purchased it, I knew it was leaking from the up-pipes pretty badly. After watching many YouTubers explain the challenges of removing the turbo, I purchased a few tools and parts and went to work this weekend. I spent most of Saturday working on the two lower nuts, broke my flex socket, and returned to the drawing board. I watched several more YouTubers, all had the same flex socket "solution." Frankly, that's a crap solution, but with tools available on the market may be the best you can buy.
Instead of buying another flex socket, I made a tool to fit the workspace. Excuse the crappy welding from the $80 Harbor-Freight flux core:
You must be registered for see images attach
This was my second try after using a socket and wrench from Menard's. It failed to hold on to the nut. 1/2" drive also had clearance problems on the driver's side.
You must be registered for see images attach
After the Menards house brand failed, I watched a couple of Torque Test Channel videos to find a good boxed-in 12pt wrench. The Craftsman tested really good, and Lowes had the 15mm in stock. (I wasn't about to cut my USA-made Craftsman wrench). Using wrenches on the shelf, I found that a 16mm would fit over it. They didn't have a 3/8" drive 16mm 6pt impact socket, so I bought a chrome one.
I cut the socket open to two opposing edges and welded the wrench in to allow 1 1/4" clearance. I cut the wrench off and rounded it back off on the grinder.
1st, hit with my impact, and the nut turned. A few minutes later, I had both sides off.
Here are a few other pictures of the home-made tool:
You must be registered for see images attach
You must be registered for see images attach
You must be registered for see images attach
You must be registered for see images attach
It took me about 30 minutes to make version 1 and about 15 minutes to make version 2. Had I seen this information elsewhere, this is where I would have started.
If you decide to make one of these, be sure to grind off the chrome or zinc plating before welding. You don't want the toxic fumes that will be produced.
I hope this helps someone else looking to do this job.
I will duplicate this post on other forums where OBS Powerstroke people roam.
