Thread: Friggin wastegate keeps falling off

I want BOOST!!! and this damn thing keeps falling off. Any ideas on how solve this issue for good will be welcome. It is a tial 38mm, regular 2 bolts flange, it has happened 3 times in like 2 weeks, the most annoying part (apart from the car suddenly gong from superfast, to superslow lol) is that i have to take everything off to fix it (turbo, downpipe, manifold...)

1st time: Both of the bolts that hold the wastegate to the manifold snapped, it fell and got stucked in between the crossmember and the exhaust (at least it didnt fell to the ground at like a 100mph, but i lost my little metal gasket ) I put another gasket (regular non metal gasket), changed the bolts and tighten them like there was no tomorrow. Fixed.

2nd time: 2 days after, noticed my car was making full boost at like 6000rpm, checked the WG, and it was completely loose and about to fall off again, I didn't hear the giant exhaust leak cause I'm running open downpipe, off course the leak burnt the gasket I just made . Made another gasket again, this time being sick of this I put long bolts tighten them, and this time I installed nuts on the other end of the bolts to make sure is not getting loose again. Fixed.

3rd time: Car feels so fast I wanted to vomit, and suddenly it started making full boost at 6500rpm and on the way home it became N/A lol. Got home, checked the WG, one of the bolts snapped! Haven't touched the car since then...

I need a definite solution to this!!!

Longer bolt, locktite & lock washers.

Longer bolt + lock washers, thats what failed on the 3rd time. :P

Are the bolts snapping, or are they backing out?

If they are backing out, safety wire is an option. Red loctite might help a bit (but not much at those temps). Some type of crush washer or lock washer can help too. Locking nuts (those copper ones) on the back side might also be an option. Converting to studs instead of bolts might also help. Again, locking copper nuts.

If the bolts are sheering, then you just need stronger hardware that can handle the temps. Shouldn't be too hard to find.

Maybe switch to studs?

Or...weld the bolts onto the manifold (you COULD try jb weld, but I'm not sure what that's rated for, as far as temp rating)

1st and 3rd time, snapped bolts, 2nd time backing out...



Hmm welding studs to the flange, I could try that.

Could it be that the backfires are burning the non-metal gaskets, then that gets the bolts loosen, then they snap?

vband

Grade 8 standard bolts or 12.9 metric bolts, and the locking nuts that look like they are nuts put in a vice and smashed just slightly...if that doesn't work, go with ARP hardware...

Most likely, yes, it's heating up the bolts, but they aren't secure enough, so combination of rattling plus heat will break the bolts.

Happened to me. But lock nuts and washers, and high-temp threadlocker (1500+F) fixed mine. I believe I stuck some jb weld on there, just to make sure.

You could try using some machine bolts out of a motor. Maybe some grade 7 or grade 9.....