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Wastegate rod fell off on the road ;[

2.7K views 6 replies 3 participants last post by  infamous  
#1 ·
Driving from work tonight, suddenly no boost. Stopped at the gas station, popped the hood - of course! The actuator rod slipped off the wastegate arm. What's worse, the adjuster piece unscrewed itself and disappeared. And so did the locking nut.

Drove home in N/A mode. Slow. Also loud (the wastegate flap is wide open).

Tried an adjuster from T25, it didn't fit - looks like TD04 has a different rod length and thread. Will have to fabricate something tomorrow.

*sigh*
 
#3 · (Edited)
Sorry to hear about your luck.
I'd heard about the wastegate rod issue, so when I had my turbos, I used some LocTite on the threads and wrapped the end clip(s) with some fine bailing wire to insure that the connectors stayed connected.
A possible alternative for you to try (if you can't come up with a replacement) is a screen door's turnbuckle assembly. They generally consist of a pair of eye hooks on either end of the threaded knuckle that comes in a number of sizes, perhaps even one to fit your needs? Just dispose of the eye hooks and you're good to go.
 
#4 ·
Ended up adapting a sturdy L-shaped metal bracket. Cut to size, drilled two holes and cut the thread in the end that screws onto the actuator rod. Added a lock nut for security.

The thread on the TD04's rod is odd, I measured M6x0.8mm (while the standard size is M6x1mm). Couldn't find a suitable metric tap, so I used a 1/4"x#28 (had to re-thread the nut too). Seems to be holding fine. Adjusted the base boost and went for a ride - good boost all the way as it should be.
 
#5 ·
Great and congratulations on your fabrication/mod-ability, you should post some pics so that fellow Saabers could gain a little insight should they find themselves in a similar situation.