I think I'll give the k04 wheel a shot, it's only 50 bucks and I have a spare turbo now... why not.

2 questions, it looks like the front housing is held on by 3 or 4 nuts, what kind of seal is between the two halves? Any idea where I can get one?

I suppose I need to get the thing balanced again after popping a new wheel on, huh?

 

I think BorgWarner has a swap system to repare turbos

 

I'm tossing a K04 compressor in a K03 housing. I like to think of it as a poor man's K03 sport in a configuration that will work in our cars.

No one has really been able to say if it will work, or even be beneficial, so what the hell. I'm game.

 

I mean theoretically it would work but kinda weird way to go about it I would say, No?

 

My turbo is going out, I got a used 03 for 115 bucks, and the compressor wheel is 51 bucks. Seemed like a brilliant idea to me (and I'm cheap )

I'm an auto, I don't want full on K04 power, I just want more topend... so if it breathes even a LITTLE better than a K03, well I've accomplished my goals.

 

I am not certain, but I believe you will need to obtain a "K-04" compressor housing to fit the larger compressor impeller.
Most Diesel Fuel Injection Pump Specialists will have a turbo rebuild kit available for about $100.00, or less. A kit provides new bushings, thrust bearing, labyrinth seal rings, circlips and all the seals and "O" rings for the assembly. I have seen these kits on eBay also. Only buy the genuine KKK/Borg Warner parts kit.
The compressor housing is sealed to the backing plate with an "O" ring fitted around the OD of the backing plate. That part is available separately from an authorized rebuilder shop.
Tip: First, remove the turbine housing from the center section. Next, arrange to hold a socket that fits the hex at the turbine wheel hub in a vise. To remove the compressor impeller, set the hex of the turbine wheel hub into the socket. Now remove the compressor impeller retaining nut. Next, heat the compressor impeller to about ~200 to ~220 degrees or so with a heat gun. Grip the impeller with a rag and rotate and pull at the same time to carefully work the impeller off of the turbine shaft. You will need to stop and re-heat the impeller as needed. To install the replacement compressor impeller, heat to ~200 to ~220 as before and quickly push it onto the turbine shaft. Apply some Locktite "Red" thread locking compound to the turbine shaft threads and using a NEW retaining nut, tighten it to the specified torque.
Please be sure to post the results after you have had a chance to evaluate this setup on your car.

 

that is very helpful.

the compressor wheel will fit, there are two wheels listed, one for hte K03, and one for the K03/K04.
I'm assuming this is the one used in the K04 and the K03 sport turbos, just a guess. It's really hard to find any info on them.

 

Ahh well reason well justified