L8 APEX
10-14-2003, 08:36 PM
I was brought a Lightning to straighten out after another local shop had installed a lot of mods including a KB. The truck was taken back to the other shop a few times to try and fix the problems. The boost gauge didn't work, it would idle like crap and die at stop lights, threw misc engine codes. I found the upper intake and supercharger assy was leaking profusely. I removed it and found stripped out bolts, chips and other case damage. I have installed a few KB's and am familiar with how sensitive they are on install and torque specs. While removing the charger I had to use a 1/2" breaker bar to loosen the case bolts:eek2: . This was a bad sign as KB specs read 20ft lbs. The manual even says in bold print, 20ft lbs. not 22 or 25 WILL CAUSE DAMAGE! These were at least 60-70 ft lbs. What happens when the case is over torqued it takes a set and the rotors wear accordingly. Problem is when you remove the charger the case is warped. When it is reinstalled and torqued to 20ft lbs it runs for a few minutes then locks up when it reaches temp. I called KB Tech today and this is exactly what happened to this charger.
I will attach a few pics of what I found today. You will be looking for bad seals where it sucked in water and blew out oil. I srayed the engine with water to find the vacuum leaks, you can also see where the boost has blown oil vapor out of the leaks and collected dirt. Also with a KB you have to use shorter intake bolts. They used the stock bolts and cracked the fricking case and stripped the bolts! If that chunk would have fallen in the chrager it would have locked it up instantly. I resealed the surfaces and drilled and tapped the adapter plate, filed smooth whatever it took to repair the damage. It is a shame that this was done by a local shop and ended up ruining a new KB:rolleyes: .
The broken boost gauge had the line pushed into the gauge but not fastened in a compression connector. The spark plugs were so tight I had to use a bar to break them loose also. I wish I could have done the job to begin with and helped to avoid this disaster. It adds up when you have it done twice.
I will attach a few pics of what I found today. You will be looking for bad seals where it sucked in water and blew out oil. I srayed the engine with water to find the vacuum leaks, you can also see where the boost has blown oil vapor out of the leaks and collected dirt. Also with a KB you have to use shorter intake bolts. They used the stock bolts and cracked the fricking case and stripped the bolts! If that chunk would have fallen in the chrager it would have locked it up instantly. I resealed the surfaces and drilled and tapped the adapter plate, filed smooth whatever it took to repair the damage. It is a shame that this was done by a local shop and ended up ruining a new KB:rolleyes: .
The broken boost gauge had the line pushed into the gauge but not fastened in a compression connector. The spark plugs were so tight I had to use a bar to break them loose also. I wish I could have done the job to begin with and helped to avoid this disaster. It adds up when you have it done twice.