BorgWarner Turbo Rebuild Service

PT Turbo rebuilds and remanufactures BorgWarner turbochargers in-house at our San Bernardino, CA shop. Every unit goes through a full teardown, OEM-spec or better parts replacement, CIMAT VSR balancing, and final quality inspection before it ships back — backed by a 12-month unlimited mileage warranty and nationwide mail-in service.

Best For

• Detroit Diesel and Caterpillar truck engines
• Performance diesel and gas builds (S-Series, EFR)
• European diesel (K-Series, KKK)
• Heavy-duty commercial fleets

Shop BorgWarner turbochargers in stock at PT Turbo →

BorgWarner Models We Rebuild

About BorgWarner Turbocharger Rebuilds

PT Turbo has been rebuilding BorgWarner turbochargers since 1978, covering everything from S300 and S400 frame units on Detroit Diesel and Caterpillar truck engines to S-Series and EFR performance turbos on built diesel and gas applications. We disassemble each unit completely, inspect the center housing, bearings, thrust system, and wheels, then rebuild to BorgWarner clearance specs with a final balance.

For fleet operators and performance builders, a rebuild is usually the smarter call. A genuine BorgWarner replacement carries a long lead time and a premium price, while your existing housing and turbine assembly are often still serviceable. Rebuilding the core you already have keeps the unit matched to your application and gets the truck or build back running for a fraction of replacement cost.

Common BorgWarner Applications

Heavy-Duty Commercial and Truck Diesel

• Detroit Diesel Series 60 and DD-platform engines running S400 frame turbos
• Caterpillar C-series truck and industrial engines
• Class 7 and Class 8 fleet trucks using S300 and S400 units
• Agricultural and off-highway equipment

Performance Diesel and Gas Builds

• S300 family: S363, S366, S369
• S400 family: S467, S472, S475
• SX and SX-E billet-wheel units: S300SX, S300SX-E, S200SX, S200SX-E
• EFR series for street, drag, and motorsport applications

European and Smaller-Frame Diesel

• K-Series and KKK heritage units on European diesel platforms
• S200, S257, and S360 frame turbos
• Light commercial and van diesel applications

Common BorgWarner Turbocharger Symptoms

• Excessive shaft play, both radial and axial, common on S400 units that have seen high-boost tunes
• Oil leaking into the intake or exhaust side, often from worn piston ring seals after high mileage on S300 frame turbos
• High-pitched whining or siren noise from worn journal bearings or wheel contact
• VGT or actuator sticking and erratic boost on variable-geometry truck applications
• Low boost or slow spool from a damaged compressor wheel or worn bearing system
• Overboost and boost creep, frequently from a stuck or maladjusted wastegate on S366 and S369 units
• Black smoke under load caused by reduced airflow from compressor or turbine damage
• Bearing failure with metal in the oil drain, often traced to oil starvation or contamination

Real BorgWarner Failures We See in Our Shop

• On the S400 frame units we rebuild, we frequently see compressor wheel over-speed damage from aggressive fueling tunes. The wheel gets pushed past its safe map and the blade tips crack or shed, often taking the bearing system with it.
• We see thrust bearing failure on S475 and S472 builds running back-to-back full-boost pulls. The thrust load from rapid spool and high drive pressure wipes the thrust collar and bearing, showing up as axial play and oil leakage.
• On high-mileage S366 and S369 turbos off fleet trucks, the piston ring seals on the turbine side wear and let exhaust gas pressurize the center housing, pushing oil out the compressor side. Owners often mistake this for a failed seal when it is really blow-by behind the seal ring.
• We get plenty of S300SX-E and S200SX-E billet-wheel units in with bearing damage from oil contamination and delayed oil delivery on startup, especially on builds without a properly plumbed feed line.
• On Detroit Diesel and Caterpillar applications, we see turbine-side coking and bearing failure from hot shutdowns. Shutting the engine down hot bakes the oil in the center housing and starves the journal bearings on the next start.
• VGT-equipped truck units come in with sticking vanes and lazy actuators from soot and carbon buildup in the nozzle ring, causing erratic boost and the limp-mode complaints fleets bring us.

Frequently Asked Questions

How to Identify Your BorgWarner Turbo

The identification tag is typically located on the compressor housing, bearing housing, or center section of the turbocharger. It usually lists the model number, assembly number, and serial number. If you’re not sure which BorgWarner model you have, send PT Turbo a photo of the tag and we’ll help identify it before you ship anything.

PT Turbo Warranty

• 12-month, unlimited mileage warranty against defects in parts and workmanship
• Final quality inspection on every rebuild: leak test, visual inspection, actuator or wastegate function check
• In-house CIMAT VSR balancing with a balance report included
• Nationwide mail-in service — you don’t need to be local

Why Customers Choose PT Turbo

• Rebuilding turbochargers, including BorgWarner, since 1978
• In-house CIMAT VSR balancing on every unit, not outsourced
• Full housing sandblasting and OEM-spec or better parts replacement
• Inspect first, quote before work begins — no surprise charges
• Nationwide mail-in service from our San Bernardino, CA shop

PT Turbo Inspection Process

Every turbocharger goes through the same evaluation before any work begins:

1. Initial evaluationcompressor wheel, turbine wheel, shaft, bearing housing, VGT assembly (if equipped), actuator, and seal surfaces are checked first.
2. Complete disassemblythe turbocharger is fully torn down and every major component is inspected individually.
3. Cleaningcomponents are cleaned to remove carbon, oil residue, rust, and contamination.
4. Measurementcritical tolerances are measured against OEM specification.
5. Reassemblyrebuilt using new wear components matched to your specific model.
6. CIMAT VSR balancingthe rotating assembly is balanced in-house, with a balance report included.
7. Final inspectionleak test, visual inspection, and actuator or wastegate function check before shipment.

No work begins without your approval. You receive a quote after inspection, not before.

Common BorgWarner Turbo Models We Service

Pricing

Most rebuilds require inspection before final pricing. Standard rebuild pricing depends on the turbo model, parts availability, wheel condition, shaft condition, housing damage, and whether upgrades are requested. PT Turbo inspects every turbo and sends a quote before any work begins — no surprise charges.

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