Automatic Waste Gate Switch Failure

[petchyboy]

Hi all,

Just had a new exhaust system and cold air put on my 09 FT XR6 Turbo, which took it from 213RWKW to 278RWKW. But since then had major issues. Initially it was the inter cooler pipes which were splitting at the clamping points and coming off, typical cheap rubber. These have now been replaced with stainless steel piping.

Next to go was the Waste gate switch, which basically let 80% of my boost go. Currently my tuner has a manual bypass in, with the boost set to around 8psi as opposed to the factory 13psi, to be safe until a permanent fix can be sorted. Just wondering if anyone else has had similar issues after these types of modifications, and any solutions for this? As we haven't adjusted boost or any other factory settings, it seems weird that this part would complain and not function correctly. The boost does come on 500RPM earlier but I wouldn't think this would matter?

At this stage I'm not looking at getting a tune done until warranty expires, the dyno showed the AFR was all good, and no other reasons to be alarmed.

Thanks for any feedback

[Gloo]

Did you ever think your problems are because you have put an exhaust and CAI and didnt tune your car to suite?

213 rwkws is very low for a stock fg. Minium is around 230ish, some people have had up near 260ish. And you cant put a full exhaust on a xr6t of any model without sh*t braking or the ECU losing its sh*t. Take the exhaust of, send it back to fords for a factory retune or keep the exhaust and get a full custom jobie.

Sorry I dont have any help on your wastegate switch problem, im just letting you know what every one else will soon tell you any way.

[petchyboy]

Thanks for the reply, I asked the question many times of different people about needing the tune, and the verdict was if it is dyno'd, and the result of the AFR was fine, and it wasn't over boosting then it wasn't a problem? I'm not exactly car smart, but speaking with different people and performance companies, this was their response. Not knowing much about it I can only go off what these 'professionals' tell me.

The low rwkw result was unexpected, but the gain of the exhaust and CAI, was more than expected.

[ZAP]

I would say you are being fed porkies.

An Exhaust should cause your car to overboost and require a tune if it is any good.

To tell you that a exhaust and CAI has given you 65rwkw is taking it to BS levels.

Firstly any decent exhaust that flows better than stock is likely overboost these cars.

Second, I highly doubt that your "wastegate switch" has anything to do with it.

Does your tuner do a lot of XR6 Turbos ?

There are heaps of experienced people here that can help you.

[petchyboy]

Thank you for the reply, the shop that has done the work has tuned many Xr6t and I have the dyno sheets to confirm the power gains. But the more research I do into the matter seems more than likely that I'll have to get it tuned now before something else goes completely pair shaped. The whole spec I asked for was extra performance without voiding the new car warranty! Seems now I either suffer the financial loss and go back to stock, or get the tune and 'hope for the best' that nothing goes wrong during the warranty period that will cost me extra dollars......

With the over boost, I was told the ECU had certain parameters that it works to ensuring that situation doesn't occur, the same goes for the AFR. I find it hard to believe that a reputable, established performance company could be so misinformed about all of this?

Anyway sounds like the only solution really is the tune.

Edited 27/07/10 05:58 AM by petchyboy

[Gloo]

Yeah it was strange your first power figure, but who knows.

It is good that your AFR's were fine. But that only means your not likely to damage anything due to that, doesnt mean that everything else will still be fine.

As far as I know if you install a full exhaust onto a FG you need an stronger actuator. Maby your issue is that your stock acctuator is not strong enough and it cant hold boost?

EDIT: SORRY I ATE LUNCH WHILE POSTING DIDNT CHECK TO SEE FOR UPDATES...

Edited 27/07/10 06:02 AM by Gloo

[sexual harrassment panda]

Thank you for the reply, the shop that has done the work has tuned many Xr6t and I have the dyno sheets to confirm the power gains. But the more research I do into the matter seems more than likely that I'll have to get it tuned now before something else goes completely pair shaped. The whole spec I asked for was extra performance without voiding the new car warranty! Seems now I either suffer the financial loss and go back to stock, or get the tune and 'hope for the best' that nothing goes wrong during the warranty period that will cost me extra dollars......

With the over boost, I was told the ECU had certain parameters that it works to ensuring that situation doesn't occur, the same goes for the AFR. I find it hard to believe that a reputable, established performance company could be so misinformed about all of this?

Anyway sounds like the only solution really is the tune.

exhaust = no warranty, changed pipework = no warranty, tuner fiddling with settings = no warranty.

By the way the xr6t's are 9 psi stock, the f6's are 13

[petchyboy]

I will definitely raise the actuator theory with them and see the response I get. Car is going back in on the weekend or early next week, very frustrating to be getting messed about. Cheers for all the help, will post back when I know more.

[Gloo]

The stock actuator should hold stock boost fine, so I doubt it is that I was just chucking ideas in the air. Let us know how you go.

[petchyboy]

Ended up getting a tune done, although very mild one at this stage. 280rw Kw, and 550Nm. According to CAPA they have had a few cars come through with really low stock results and all of them have been fleet cars. Is it possible that ford are detuning the fleet cars for extended life? Make sense if this is the case considering the improvements I got from just the exhaust.