I had replaced my TB seals a while back and everything was fine for a year and a half. Then a leak test showed what appeared to be a major leak in that area, I couldn't build a pressure in the system at all with 65 psi in a bottle behind it. I thought the seals may have somehow gone bad and went and replaced them with MIL.Spec seals.

I did another leak test, and its still leaking the same way from the same area around the TB. Is there anything else in that area that can leak? The hiss is very quiet and is hard to hear; almost like its coming from behind/underneath the TB. The air coming out of my 5 gallon bottle is much louder than the leak sound.

 

I too had my factory Throttle shafts seals go bad, no big deal, happens all the time, wasn't even that hard to replace.....But then just like you, the leak came back about a year later(I could hear the leak under high load) Then one day my upper intercooler pipe blew off my TB, Which Lead me to figure out that I was actually hearing a leak at the TB to Upper intercooler rubber elbow connection. I replaced the factory hose clamp with a T-clamp and the leak did not go away. After that I finally did a boost leak test to make sure the seals were not leaking again, which they were not. While doing the leak test I could physically see the rubber elbow expand to the point where it would pull itself out from under the clamp and cause a leak. So from there I tried putting another clamp just on the other side of the TB lip on the rubber hose along with the T-clamp. This worked for a while, But I was still getting the occasional audible boost leak, so I also placed a 3rd clamp about 2 inches up the rubber elbow to help keep it in shape while under boost, Since doing that I have not heard any more boost leaks.

I'm not saying this is your problem, but look into it. The throttle seals go out a lot, they could have gone out again for you. If I were you I would find a air compressor to use during your boost leak test, a 5 gallon bucket does not have enough volume to do a good boost leak test.

 

whoops

 

I have a 1 gallon pancake compressor that I can use to get my bottle up to about 80psi. My leak so bad that I can't build a pressure at all. I can probably charge the bottle to its limit with another compressor. I actually broke the end off the TB hose clamp, if I take it off I will probably never get it back on; there's not enough left. It tightened it pretty good. I suspected that the clamp could be a culprit. I guess I can see if I can find something else to use.

I've been looking for a reason to chuck the upper IC hoses too over the stockers (2003, could be an old age prob with the hose end), but can't justify the cost quite yet.

 

There are 3 freeze plugs on the bottom of the tb within the iac circuit.....maybe the leak is coming from there....


flip the tb 180° & conduct the test again & spray some soapy fluid on them & look for bubbles...

i always use a thin layer of rtv between the tb, gasket & im.

good luck.

 

I would replace that clamp before you waste anymore time, if its in as bad of shape as you say it is, theres a good chance its your problem. Replace it with a nice T clamp from Napa or any other parts store, then go from there.

 

What gets me is that the clamp must be BAD if I can't build any pressure at all. I haven't been able to find a T-clamp that fits at my local auto parts. I can put another hose clamp on it for now; I think my chances of getting the stocker back on are slim.

I used a thin film RTV on the TB gasket (both sides) when I put in the mil.spec seals. I'm worried about messing the gasket up if I have to pull the TB off again. I used soapy water around the TB / upper IC pipe connection before I put in the mil.spec seals, I didn't see any suds. I'll try the soap thing again when I have time to do another leak test.

 

I work at a Napa in MD. I've bought a couple T-bolt clamps from here. Try the part numbers 705-1531 or 705-1532 and that should be what you need. They might have to order them so give them a call earlier in the day, but there won't be any charge for it. Hope that helps some

 

I have seen leaks from the gasket as well. Something to look into to make sure the t/b is properly torqued.

 

I torqued the TB bolts like I was putting on a tire, and used a thin film of RTV since it is the factory gasket. What gets me about the leak is that it is a low pressure leak. I can't build any lasting pressure. Its like there is a hole or something in it.

I think I'm going to drench the TB in soapy water and put as much air into it as I can.

 

soapy water is the best to search for the leaks... what do you have the air pressure regulated to. I hope your not trying to dump 65psi in...

 

I use 65+ psi in the bottle; but can't build a pressure at all. It goes in the turbo and comes out almost as fast at the leak. Yet the leak is extremely hard to hear. The noise of the air coming out of the air bottle is louder.

 

yeah i heard soap water is good

 

I don't like the sound of your "bucket" method. You need to get to an air compressor. That way you can fill the system up to a steady 30 psi and be able to look around and listen for a leak.

 

Yeah I would do what CBRicard said. Then you have more time to find your problem.