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Old 01-04-2019, 10:10 AM   #1
tomasss
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Default Garrett exhaust housing cracked

I sent the turbo from my b204gt for overhaul and the shop sent me these pics today. They are stating it doesn't affect the function of the turbo and they are asking if they should proceed with the overhaul.

What do you guys think? The turbo is most probably original...around 200 thousand kilometers...





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Old 01-04-2019, 10:29 AM   #2
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Play it safe and find another exhaust housing.
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Old 01-04-2019, 01:46 PM   #3
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That part of the housing is called the tongue. A minor crack in the tongue can be considered normal in a lot of applications, but yours looks like it has migrated pretty far around the housing and is about to go through to the outside wall (if it hasn't already). Will eventually result in an exhaust leak and could even cause turbine wheel failure, worst case.

Best to replace this housing unless you know a really talented welder who wants to spend a bunch of time fixing it.
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Old 01-04-2019, 08:49 PM   #4
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Looks like time for a replacement housing. As a suggestion because you are across the pond you can more easily procure the cosworth sierra T3 exhaust housing. I am using the .48 housing in my 240 turbo. Fit right on without any issue to my stock T3 center and turbiine wheel. The sierra housing has a 3" outlet and larger wastegate opening and puck. Had to fabricate a bracket for the wastegate actuator. Better flow and boost control than the stock setup.
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Old 01-05-2019, 04:57 AM   #5
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Ok, I will check with my welding guy and also look around for some replacements.
For the cosworth housing - where do you look for these? I just quickly checked ebay and seems to me these things are pretty rare...also it means I would need a different downpipe as the original one is 2.75"...
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Old 01-05-2019, 09:02 AM   #6
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Is this the part I am looking for?

https://www.ebay.com/itm/Garrett-T3-...-/382545965408

Edit: nope, it has different downpipe flange

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Old 01-05-2019, 10:53 AM   #7
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According to this page also a turbo from Lotus esprit is the same Garrett...could it be this one?
https://www.ebay.co.uk/itm/Lotus-Esp...7/143020083260
And then connect it via this downpipe https://www.ebay.co.uk/itm/LOTUS-ESP...F/291946498157

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Old 01-05-2019, 11:32 AM   #8
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The lotus turbo turbine housing is similar or might be the same to the cosworth housing.
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Old 01-06-2019, 06:47 AM   #9
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Anyone here is able to confirm if the Lotus turbo above (sticker saying TB0373 465133-3) will fit the stock turbo?

Or, anyone has/knows where to look for the replacement housing from Lotus/Cosworth other than ebay?
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Old 01-06-2019, 04:40 PM   #10
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What's the Garrett part number of the stock turbo from your B204?
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Old 01-06-2019, 05:34 PM   #11
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Tb038 465177-0004
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Old 01-07-2019, 07:35 AM   #12
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So, I called one guy that is specialist in Cosworth...he has these turbos in stock...stating it is from Sierra/Escort Cosworth. But he measured the downpipe opening and it is definitely not 3" as dl242gt stated, more something like 2.5". There is "M4" written on the casting.

Could someone confirm if it is the correct one or not?








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Old 01-07-2019, 01:47 PM   #13
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That housing ^ is 0.83 A/R, which will flow a lot more than the 0.48 A/R that everyone seems to like. It will also make for lazier boost response.
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Old 01-07-2019, 02:50 PM   #14
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Read that casting carefully...it is not 83 but 63...and according to >this< topic it is as good as 48...
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Old 01-07-2019, 03:00 PM   #15
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Quote:
Originally Posted by tomasss View Post
Tb038 465177-0004
Your stock turbo has a 0.48 A/R turbine housing, with the stepped Volvo T3-style inlet flange, and the outlet flange has a 64.5mm inner diameter, with a 100mm bolt circle for the 3-bolt flange.

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Originally Posted by tomasss View Post
Anyone here is able to confirm if the Lotus turbo above (sticker saying TB0373 465133-3) will fit the stock turbo?
This alternate turbo 465133-0003 also has a 0.48 A/R turbine housing, but the inlet flange is flat (not stepped like the standard Volvo). The casting material should be there to modify the housing by cutting the stepped diameter. Bolt pattern is the same.

Outlet inner diameter should also be the same, but the bolt circle diameter is 110mm so you'd need to modify your downpipe flange to bolt on.

The internal interface dimensions with the turbine wheel are the same, so no issues with functionality.

Biggest difference will be the wastegate arm & valve is in a different location inside the housing. Your original turbo has the arm rotation axis parallel with the turbine inlet flange (3:00 position looking at the outlet with the inlet flange pointed down). The 451333-0003 has the rotation axis rotated up by 55 degrees (~1:30 position). So your wastegate actuator bracket would need to change accordingly to line up with the new crank arm position. If you were able to grab the actuator and bracket from the 451333-0003, I think you could make it work.
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Old 01-07-2019, 03:01 PM   #16
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Quote:
Originally Posted by tomasss View Post
Read that casting carefully...it is not 83 but 63...and according to >this< topic it is as good as 48...
Fair enough, looked like 0.83 but I see it's 0.63 now. Regardless, still bigger than your current housing and will change the boost response, wastegate %, & turbine flow. Not to say it would be a bad change - performance may improve depending on your engine & tuning.
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Old 01-07-2019, 03:08 PM   #17
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I put a .60 AR housing on the last project and it works great.
The .48 housing is liked because that is what they come with (cheap), a great device to strangle your motor.
It's made for soccer mom's not Maria Andretti
Combine that with a large compressor and you get boost at cruise on the freeway!
And no mileage due to boost afr's and timing.

The stepped manifold can be fixed with an adapter from ATP
https://www.atpturbo.com

I ordered a GT3071 with the .60 / .60 and a 3" outlet
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Old 01-07-2019, 03:17 PM   #18
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Quote:
Originally Posted by Duder View Post
...
Great and valuable info, thanks...I will keep that Lotus turbo in mind in case the guy asks too much for the separate cosworth turbine housing...

What I still don't get...it has been mentioned several times that the cosworth turbo has 3" output to the downpipe AND it fits the stock downpipe. How is that possible if the original turbo has 64.5mm (roughly 2.5) output to the downpipe? Or is the 3" outer diameter?
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Old 01-07-2019, 03:19 PM   #19
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Quote:
Originally Posted by Duder View Post
That housing ^ is 0.83 A/R, which will flow a lot more than the 0.48 A/R that everyone seems to like. It will also make for lazier boost response.
Actually its an Escort Cosworth .63 turbine housing...like this one here----->
Looks like ordinary Sierra 2wd Compressor side--with that wastegate actuator bracket bolted on the back side like that (4x4 compressor housing has the bracket on the front side..and Escort Cosworth is bigger (and nice for 315 to 400 bhp) and the wastergate actuator bracket is cast in like



The outlet HOLE on the turbine housing is 64mm or so...

It is the bolts for the downpipe and the register for the down pipe which is set up to accommodate 3" without bogus reducers....
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Old 01-07-2019, 03:34 PM   #20
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Ok, understood. That explains why the stock down pipe fits then.
So do I understand correctly, talking about the exhaust housing only: when in the >other< topic two versions (.48 and .63) of the turbine housing were discussed, the rusty one I posted is the second one and will fit and work as described there?

I am really newbie in turbo's, sorry guys for dummy questions..
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Old 01-07-2019, 03:52 PM   #21
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The rusty one you posted photos of looks to be dimensionally the same as the Lotus housing you were asking about. 110mm bolt circle, and wastegate arm clocked differently vs. your stock turbo.

John V has the most experience of any of us here with these ancient Cosworth / T3 turbos, so I'll defer to him to answer questions about implementation or performance preference of one housing vs. another.
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Old 01-07-2019, 04:45 PM   #22
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With the B204FT exhaust manifold you gotta be careful about clearances against stiff like the block, intake hose, heater pipe, oil return, etc. Once you start changing turbine housings the wastegate setup may end up being too close to these components.
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Old 01-07-2019, 05:55 PM   #23
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Sure. I am not willing to try anything untested. But as far as I understand the .63 is the one that JW240 is using in his setup.
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Old 01-07-2019, 06:49 PM   #24
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Quote:
Originally Posted by tomasss View Post
Sure. I am not willing to try anything untested. But as far as I understand the .63 is the one that JW240 is using in his setup.
I have only driven various cars with the .48 housing..
YBG 4x4 Cossie
2,3 8v Volvo--several
2,3 8v Ford Lima in Us Sierra

And reports from a number of others with B21T, Mitsubishi 4G63 Galant, USDM Misterbitchi Eclipse with 4G63, Volvo 2300 16v

All report a motor that pulls HARD from 2200-2300 rpm and if the motor has the ECU for it, revs past 7000 happily...

The .63 turbine housing in this design was OEM on first 2500 Escort Cosworths for use in Group A rally....which mandated the turbo Ford intended to use on the rally cars in International competition must be on the base homologation cars...so they used TB3403 with the .63 exhaust housing....
But bear in mind that that was so its there when car is in Group A trim...which meant aggressive anti-lag giving just short of 1 bar boost at idle (and idle was around 1400 rpm) and a VERY close ratio 6 speed versnellingsbak so they weren't worry about the car falling off boost on gearchanges because the rpm didn't drop more than 800-1000 rpm, and anti-lag...

The base model "large turbo" Escorts were the slowest stock Cossies because big A/R lag..

I'm guessing but I'll bet you don't have plans for a very close ratio box or aggressive anti-lag. If my guess is right, I would suggest the .48 housing..

And that's assuming as well that this is for a road car, not a track car.
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Old 01-07-2019, 08:07 PM   #25
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I am using the sierra cosworth .48 housing. I think it is from the 2wd cosworth car. Bought it on ebay UK. It is on a B21FT that has a 405 head with flow work, v15 turbo cam and 90+ exhaust manifold. Kjet and some other stuff. If it was on an engine with the 8.7 compression instead of the 7.5 mine has. it would even more fun. I'm going to use one on my next engine.
I use a flared 3" pipe directly out of the turbine housing.
I've seen T3 type wastegate actuators with an offset arm. That may help with the actuator location change. Mine is at an angle so it isn't as smooth operating as I would like.
https://www.ebay.com/itm/Garrett-Int...ytgy:rk:4:pf:0

Another affordable setup is the five bolt T3 .63 exhaust housing as used on a 240 turbo. That combined with the ATP ultimate gate has worked for people.

Last edited by dl242gt; 01-09-2019 at 07:49 PM.. Reason: spelling
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