2008 Ford Super Duty 6.4 Dual Turbo - Exclusive Look at How They Are Built

The high-pressure VTG turbine wheel and shaft assembly are fit with a pair of journal bearings and assembled into the bearing housing by a robot. A BorgWarner engineer mocked up this display for us so you can see the precise arrangement.

If the turbine shaft, journal bearings, and compressor-wheel assembly don't pass BorgWarner's quality-control tests where the assembly is spun to its rated rpm, the bearing housing is disassembled by a line worker to find out why.

While the bearing housings are being assembled, the VTG components are set into individual fixtures and installed into the turbine housings on another assembly line.

The high-pressure VTG turbo-bearing cartridges are then married with their turbine housings.

The low-pressure, fixed-geometry turbo is then joined with the high-pressure VTG side, and the assembly finally becomes recognizable as what's installed on the new '08 Super Duty.

Ten feet down the assembly line, the BorgWarner dual-turbo system is complete. This specially built hoist lifts the completed unit at each end so it can be placed on a pallet for shipping.

Four complete turbo systems are placed on each layer and sealed with special plugs to prevent debris from entering them during shipping. From here, the turbos are shipped to International engine plants in Huntsville, Alabama, or Indianapolis so they can be bolted on to 6.4L engines.