Ford PowerStroke turbo rebuild

The 7.3L PowerStroke runs a Garrett fixed-geometry single turbo: TP38 on 1994.5-1997 trucks and GTP38 on 1999-2003. The 1999+ GTP38 added a wastegate and revised compressor housing. These are among the most durable turbos ever bolted to a pickup, and most failures we see are age and oil-quality related rather than design issues. Bearing wear, seal leakage from worn rings, and compressor wheel erosion from decades of service are the standard findings. Billet compressor wheel upgrades available during rebuild.

Applications: 1994.5-2003 Ford F-250 / F-350 / F-450 / F-550 Super Duty / E-Series 7.3L

• 466163-9012
• 702012-0012

The 6.0L introduced the Garrett GT3782VA variable geometry turbo to the PowerStroke line. The VGT vanes adjust exhaust flow to the turbine for faster response and integrated exhaust braking. The design works well when clean, but the 6.0L EGR system feeds soot back through the engine and the vanes accumulate carbon until they stick. A stuck unison ring is the defining 6.0L turbo failure. Every GT3782VA rebuild here includes complete vane assembly disassembly, cleaning, and inspection, not just a CHRA swap.

Applications: 2003-2007 Ford F-250 / F-350 / F-450 / F-550 Super Duty / E-Series 6.0L

• 743250-5014
• 725390-5006

The 6.4L uses a BorgWarner compound turbocharger system: a small high-pressure VGT turbo feeding a larger fixed-geometry low-pressure turbo. The system delivers strong low-end response and big top-end airflow, but it lives in a harsh regen-heavy emissions environment. High-pressure VGT vane sticking and bearing failures that cascade debris into the low-pressure unit are the standard findings. We rebuild the 6.4L as a matched set, always both turbos together.

Applications: 2008-2010 Ford F-250 / F-350 / F-450 / F-550 Super Duty 6.4L

• 479514
• 179514

The 2011-2014 6.7L launched with the Garrett GT32 SST, a dual-sided compressor wheel design that packages twin-turbo airflow into a single unit. It is compact and responsive but runs a small 64mm turbine that works hard on tuned trucks. From 2015 Ford switched to a conventional single-sided GT37 with an 88mm compressor that flows more and survives better. The two designs share nothing internally. Ceramic bearing wear on the GT32 SST and standard journal wear on the GT37 are the common findings.

Applications: 2011-2019 Ford F-250 / F-350 / F-450 / F-550 Super Duty 6.7L

• 851824-5001S
• 888143-5001S

The 2020 refresh brought another turbo revision with updated compressor aero and bearing system on the high-output 6.7L. These trucks are newer and lower-mileage, so most units we see have failed from oil contamination events or hard use in fleet service rather than accumulated wear. Contact us with your nameplate numbers to confirm configuration before shipping.

Applications: 2020+ Ford F-250 / F-350 / F-450 / F-550 Super Duty 6.7L / 6.7L HO