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Stuck Lindsay Wastegate

scam75

scam75

Well-known member
Afternoon all.

As you probably know my 944t is being a twat right now. Gearbox broken, followed by alternator failing and also an overboost issue. So the gearbox issue is in hand and the alternator is swapped out. This leaves my overboost issue. I have a Lindsay DPW and it is most certainly stuck shut. Does anybody have any ideas to try before I break all the studs and swear out loud on repeat as every stud breaks trying to remove it? I've tried the hammer dink to no avail, was thinking spray some WD40 into the ports as a last resort? Ideas on a postcard!

Cheers
Stuart
 
Hi Stuart...if you're going to take the wastegate apart I'd order a new diaphragm and spring from Lindsey, they come as a set, are a good price and will transform the wastegate as it's probably very tired by now. They also do shims to increase the spring pressure. However, if you are taking it apart anyway and if you have access to a lathe I'd machine one up yourself, it will have a far greater effect than the Lindsey half effort jobs which are designed to slip in without dismantling the unit itself. This affects how much the valve can open and why Lindsey state to use no more than 3 shims. IIRC I made mine out of bronze or brass with a thickness of 4.5mm, this will give a much better spool up time as it's holding the wastegate closed much longer.

Regarding removing the studs I'd try heat if all else has failed, take your time as you don't want to damage the wastegate, perhaps cut the offending nuts/bolts off and get the wastegate out on to a bench where things can be done in a more civilized manner?

Pete
 
Cheers Pete. I've just e-mailed Lindsay and they told me how to check the valve is opening and that the diaphragm is the most likely culprit. I think I'll just order a diaphragm and spring anyway as it seems there is little else that can fail.

Cheers
Stuart
 
scam75 said:
I think I'll just order a diaphragm and spring anyway as it seems there is little else that can fail.

Cheers
Stuart
Click to expand...


As far as moving parts go this is correct, when I rebuilt mine I had an engineering firm take a look at mine as I could see cracks around the valve seat and a lot of play in the guide, I gave them a spare cylinder head exhaust valve seat guide that I had, thinking they were the same. Well, they were the same size but there's no hardened seat in the wastegate, it's just a machined seat, no insert. So the seat was machined to make a good seal and a new guide fitted. That seemed to do the job, it's been on the car for 3 years now covering over 20k miles with no issues to report.
 
Great Pete, thanks. Lindsay quoting me $80 for a diaphragm, without a spring. I'm assuming postage to UK be extra! Ouch!

I will make sure tonight there is no issue with the pipe from the banjo bolt to top of wastegate and see if I can pop the wastegate open with a smidge of compressed air. Assuming pipe good and still no movement with compressed air it is safe to say the world's most expensive diaphragm needs replaced, which of course can't be done in situ! Argh

Stuart
 
It's certainly not cheap but to be fair it's a pretty special diaphragm that puts up with a lot of abuse, it's pretty large too. My diaphragm hadn't actually failed when inspected but I doubt that it would have lasted much longer.
 
Ok thanks again. I'll see what tonight brings and get one ordered if need be.

Edit to add another $35 to ship so $115 in total which I suppose is less than a hundred quid, so not too bad all considered.
 
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