The wrong TD04HL-15G?

boreddaily · Post by **boreddaily** » 15 Nov 2010, 11:04

Hello all. Just want to say this upfront, but I'm very new and very tired from a severe lack of sleep as of this initial post. So please, be gentle.

So here's my problem: I have a '96 850 Turbo Wagon and I need to replace the TD04HL-15G turbo. So I found one and took it to my mechanic this morning. Turns out it's not quite the right one. The mfg # from what was pulled from my car is 49189-01310 (OEM # 9146785). The replacement is a 49189-01300 (OEM # 6842744?).
As you may have guessed, I didn't know there where different ones and today I find that one has a straight/flat exhaust end and the other is angled (and I think there is a 3rd variation). And the new part is off by about an inch or so on the exhaust end (my apologies for not knowing the proper terms).
So outside of finding the exact part, what are my options? Is there an adaptor (flange?) that can be purchased? Or is there a different model that will match the -01310 where the turbo needs to mount to like a TD04HL-16 or -18, w/o having to modify anything to make it fit? And if it has to be an option, I would need to know how to find someone that can/will rebuild the original turbo since I or my mechanic can't do it (I live in Indianapolis, btw).
Or am I a lot closer to being SOL than I am willing to admit?

Any advice will be greatly appreciated. Thanks.

Post by **jblackburn** » 15 Nov 2010, 11:46

You can have a turbo shop knock off the flanges and re-weld them to the right ones.

Or a 16T will fit your car - but it must be from a 98 model T5 or R. A 15G from a 96 or 97 model has the straight flange as well, if you are able to just swap the turbo for another.

boreddaily · Post by **boreddaily** » 15 Nov 2010, 21:53

jablackburn wrote:You can have a turbo shop knock off the flanges and re-weld them to the right ones.

Or a 16T will fit your car - but it must be from a 98 model T5 or R. A 15G from a 96 or 97 model has the straight flange as well, if you are able to just swap the turbo for another.

Would you happen to know what the OEM part # is for the 16T that you are suggesting?

Post by **jblackburn** » 16 Nov 2010, 08:02

I don't, sorry. My computer with VADIS is no longer among the living. The 99 and later cars used an angled flange, though.

Post by **charlyW** » 16 Nov 2010, 10:00

You don't need to reweld anything

Get hold of your 15G turbo with the correct flange [possibly the rusty brown bit] undo the central clamp then with gentle but definate taps tap the brown bit off the turbo then do the same with the other one till it come off. The tricky bit is getting the parts together: You might find there is a locating pin on the rusty part to locate into the nice shiney alloy bit line them up and gently and definately tap the two parts back together replace the clamp and hey presto all is done.

I know this is the TD04HL-16T not the 15G but it shows where the code number is and will show an angle flanged turbo any flat flange turbo from the TD04 range will fit but be careful if you go above a 16T as the pressure peaks are a little harsh on non remapped cars and the 19T is a little harsh on remapped cars too which I found that out the hard way with my turbo boosting a touch too high I need a new engine

boreddaily · Post by **boreddaily** » 16 Nov 2010, 10:52

charlyW wrote:You don't need to reweld anything

Get hold of your 15G turbo with the correct flange [possibly the rusty brown bit] undo the central clamp then with gentle but definate taps tap the brown bit off the turbo then do the same with the other one till it come off. The tricky bit is getting the parts together: You might find there is a locating pin on the rusty part to locate into the nice shiney alloy bit line them up and gently and definately tap the two parts back together replace the clamp and hey presto all is done.
04112010013.jpg
04112010015.jpg
I know this is the TD04HL-16T not the 15G but it shows where the code number is and will show an angle flanged turbo any flat flange turbo from the TD04 range will fit but be careful if you go above a 16T as the pressure peaks are a little harsh on non remapped cars and the 19T is a little harsh on remapped cars too which I found that out the hard way with my turbo boosting a touch too high I need a new engine

Oddly, I was just thinking the same thing. But it sound too easy to be true. I might take a shot at it today, but what tools would I need to do something like that? As for finding a mechanic to do it in Indy has been difficult so far -- I even called a professional racing shop and they want no part of it.

Post by **charlyW** » 16 Nov 2010, 11:15

The strap bolt is a 10mm. Either a soft face or lump hammer and block of wood give the flange a few gentle taps running around the rusty part did the job make sure you tap evenly and never the alloy part.

boreddaily · Post by **boreddaily** » 16 Nov 2010, 16:32

charlyW wrote:The strap bolt is a 10mm. Either a soft face or lump hammer and block of wood give the flange a few gentle taps running around the rusty part did the job make sure you tap evenly and never the alloy part.

Say, you wouldn't know if there is a certain torque that the strap bolt should be tightened to?

boreddaily · Post by **boreddaily** » 16 Nov 2010, 16:36

Ok, I've got the swap done for now. I'll take this over to my mechanic first thing in the morning. If the used part works, I will have saved myself $800 and will be able to take care of some other nagging things with the leftover cash. I will keep you all posted.

boreddaily · Post by **boreddaily** » 17 Nov 2010, 16:25

Success!!! My shop called late this afternoon telling me that my car is ready to be picked up. I can't wait to take it for a spin. Thanks a bunch, fellas.