wycowboy said:
Getting the turbo Off is not too bad and there but getting the 3rd pedistal bolt is tricky. J
I'm guessing that wycowboy has a 94-97 truck where the pedistal comes off with the turbo. In the Super Duties they come out separately; there is one bolt where a wobbly is still helpful. I'd do the O-rings on both sides of the pedistal while it is out. Look up from underneath at the Y-pipes (from the manifolds to the casting at the turbine inlet) and if you see a soot stain where they meet the casting then the donut gaskets are leaking. Once they start to leak the pipes frequently get erroded by the escaping gasses and the pipes need replacment also.
If you are not doing the Y-pipes the difficult parts of the job will be:
Sometimes the clamps on the turbine inlet and outlet (downpipe) get stuck and don't want to come loose. A hammer and punch will often "shock" it loose where pulling and prying will not. Soak it good with penetrating oil and expect a battle (it makes it seem like a victory if it comes loose right away). If you coat all the mating surfaces with anti-sieze on reasembly it will help if you ever need to do it again.
Clean the spots where the O-rings sit with brake clean and super glue the new O-rings in, then put a little grease on the top of the O-rings. It will save you the frustration of getting it all together and finding out that one of the O-rings was pushed out when you slid the turbo in.
The dowel on the turbine inlet casting can be a bear to get aligned. Make sure that the V-band clamp is in (stretch it open and push it fully onto the casting) and get the turbo and casting mated before bolting the turbo down. You might need to wiggle it around a bit to get that dowel into its hole in the casting. I make sure that the dowel hole is clean and lubed with anti-sieze so that when it is aligned the dowel will slide in easily.
If you are doing the EBV actuator reseal: push the rod all the way in, make sure it is square (look at the rod in the hole), and measure the legnth of the rod from the eye to the housing. Set the new one to the same legnth and you probably (99% sure) will not have to worry about the adjustment. The instructions call for a pre-load measurement with a spring scale, don't get scared away but do set the new one the same as the old one.
Let us know how it goes!