Turbo Changeout - NC

Dartman48 · 07-24-2006, 10:25 AM

Over this past weekend I completed the first of my upgrades. The pyrometer is installed as is the boost gauge. Since I was to have the turbo off and out of the way, I opted to change the compressor housing to a 16cm2.
It all went very smooth until I tried to re-attach the oil return from the turbo. There is enough difference in the size of the housing, to change the mounting angle of the pipe flange at the bottom of the turbo and create an attachment problem. The bottom line is, plan on doing an oil filter change when changing the compressor size. I had to remove the oil filter to get to the pipe connector at the oil pan. I shortened the pipe and lengthened the hose to create enough flex in the return line to make a flat fit at the turbo end.
Other than fighting with the install until I fugured out what the problem was, it went pretty well, and I'm looking forward to the results. Next is opening up the exhaust system, particularly the down pipe. That's after my arms and back recover from the strain.

__________________
Mike
1993 D250 LE, 2WD, Auto, Ext Cab, LB,
BHAF, 16cm turbo, stock timing, 3/4 turn on Smoke Screw, ISSPRO gauges.

BigNorm · 07-24-2006, 11:15 AM

crank that injector pump up. You will be impressed!

__________________
93 W250, 5.9L cummins, Auto, 4WD. K&N Air Filter and a strait pipe. Injector Pump tweaked. Timing bumped up 1/8". Home made propane injection and a little bit of grindage on the fuel delivery pin!

Greenleaf · 07-25-2006, 03:57 AM

Mike,

Allow me to clear up something for you. A compressor housing is the cold (front) housing made of aluminum. The turbine housing is the hot (rear) housing made of cast iron. The exhaust housing is available in the size you described, 16cm2. The compressor housing is the same size physically on your turbo with a small internal difference depending upon the size of the compressor wheel. An example would be 54mm wheel or a 58mm etc.etc.

AS far as the turbo drain (return) line and hose assy goes......... The housing size will not have any effect on the return line/angle of the flange etc. I'm not sure what problem you encountered there but it is really odd that you encountered any problem at all.

It's possible that the previous owner cobbled a trubo together and you are not working with the OEM parts.

GL

__________________
1990 D250/1992 D250 Modified by **Smokehouse Diesel** Ashland, OH

....therefore, my brothers, I want you to know that through Jesus the forgiveness of sins is proclaimed to you. Acts 13:38

Dartman48 · 07-25-2006, 08:51 AM

You're absolutely right Greenleaf. I got careless with the terminology. I changed out the hot side for the 16cm housing. The compressor stayed stock.
As far as the oil return pipe is concerned, it was as stock as can be. The entire truck was bone stock. As I compared the 18cm and the 16cm housings, all I can figure out is that the housing sits just a little bit closer to the manifold because of the smaller diameter. At any rate, it changed the angle of the flange just enough to prevent a flat fit. So the best I could do was mod the pipe a bit. Oh well, it's done now.

__________________
Mike
1993 D250 LE, 2WD, Auto, Ext Cab, LB,
BHAF, 16cm turbo, stock timing, 3/4 turn on Smoke Screw, ISSPRO gauges.

***Ridemywideglide*** · 08-13-2006, 06:57 PM

I just swapped out my hy35 for an hx40 last night and ran into the same problem as you... Could not get the drain to line up flat..

I loosend the turbine side clamp bolts, and clocked the the compressor around until I got what looked good and flat, then bolted the drain up BEFORE tightening the turbine back down.. That way I know it was flat and won't leak..
This was my first big adventure in diesel-land, and all went well.
Today I also swapped injectors... Took 6 hours, had 1 leak (after putting EVERYTHING back together), but now no leaks, and it still runs.

But not something I look forward to again..

What size housing did you have on it before? I've noticed a lot of lag with this new turbo, haven't really had it out to run it hard yet, bet the hy35 deffinetly spooled faster... Come to think of it, I didn't look at what size the housing was before I put it on, was too excited.. Where can I find the numbers?

Brad

__________________
1996 2500 CTD, Ext Cab SLT Laramie, Longbed 4x4, 225K (rebuilt at 212K), 5 spd, 4:10's, 4 inch lift, 315/75/16's, Max Spool 2, HX40/16, Smokem's 5x012's, No plate, Hacked AFC, Autolite EGT, Boost & Fuel Pressure guages.
2005 WideGlide, Whiskers limited paint, Stage 1, SERT tuned. Soon to be 98"

albacore44 · 08-13-2006, 07:42 PM

I also just changed to an S300. Had the same problem with the oil return line. i had to purchae a pipe that fits a 2001 and cut it + add an additional piece of 7/8 hose to spilce 2 pieces of pipe together. big pain but it worked.

also I have the spool up problem . the HX-35 spooled quicker. mabee after I break this turbo in it will be better.

__________________
96 Dodge Ram 2500, ATI intake-exhaust,S300 Turbo, 4" exaust , AFE Stage 2 ,Gsk, Custom Plate (Don't know the number, but the truck is fast) , Full Monte DTT, mag hitec pan and diff cover, Snow's stage III water injection, amsoil dual-bypass, filter engineering coolant filter, Dipricol guages (Pyro,boost,trans temp,differential temp,water temp, oil temp,). Amsoil throughout

Tows my Weekend Warrior 32' Toy hauler loaded with 3 quads.

bbraden · 10-30-2006, 10:19 AM

I've talked to a lot of people about turbos and from what I gather if you put these bigger turbos on you have to have big horsepower to spin them as fast as the other ones spin. I think this is because it takes more exhaust to spin bigger turbines. I wanted a new turbo but from what I hear I think I'm gonna stick with my stock turbo. I just wanted something that spooled instantly. It doesn't sound like any of these aftermarkets do that.

__________________
99 dodge 4x4 13" Proluk Gold clutch, BHAF-K&N combo, Super X VP44, FASS, Edge comp, MODIFIED Super B Turbo, RV 275's, Quick spool manifold, 4" MBRP straight back, 3.55's, BFG A/T 285's!, somewhere north of 400 hp

Paccool · 10-30-2006, 11:36 AM

You second gen guys have the newer style turbos already on your trucks. The 35 is one the first gen guys are going to to help reduce the turbo lag that is present in the first gens with with a stock turbo. Some of the HX-35's are modified for better performance. Go to PDR and look up what they do to the turbos for more info. There are other suppliers out there that also do the mods but I am most familiar with PDR.

__________________
Stan

93 D250, PDR Twins HX35&HT3B, 60+# boost,PDR stage 2 head w/o-rings, PDR Cam, modified VE Pump, piston style lift pump, modified 5" intake w/AFE, ATS ported manifold,DTT 89% converter, 4" RIP exhaust, modified tranny, EGT/boost/tranny/tach gauges, TPS removed, a little chrome under the hood. Mag-Hitec tranny and diff. covers. Rear sway bar. Line-x bed liner, after market seats. Front end rebuilt with new springs - 2 " taller now. Single stage Water/Meth system installed. Oversized intercooler w/3" IC lines.

05 Chevy 2500 HD, Duramax W/Allison, 17" Hummer wheels w/285-70-17 BFG's, modified air box, ported turbo mouthpiece. Predator programmer.

Greenleaf · 11-03-2006, 05:48 AM

braden,

You need to spend some time at the HTT website and read up on turbo options. Educate yourself a little by reading up on what they offer. This would really help you to decide what unit would be correct for your particular application.

I'n not sure who gave you the information of the laggy bigger turbo but it's far from the truth unless your simply bolting on an HX40-50 that was pulled from a Cummins "C" This has been done and results is a spool-up time of say, two minutes.

__________________
1990 D250/1992 D250 Modified by **Smokehouse Diesel** Ashland, OH

....therefore, my brothers, I want you to know that through Jesus the forgiveness of sins is proclaimed to you. Acts 13:38

bbraden · 11-03-2006, 07:23 AM

Oh, I've just been trying to gather miscellaneous info here and there. It's mostly just common sense... bigger turbo on stock setup = turbo lag... what's the address to this website?

__________________
99 dodge 4x4 13" Proluk Gold clutch, BHAF-K&N combo, Super X VP44, FASS, Edge comp, MODIFIED Super B Turbo, RV 275's, Quick spool manifold, 4" MBRP straight back, 3.55's, BFG A/T 285's!, somewhere north of 400 hp

Greenleaf · 11-03-2006, 10:15 AM

www.htturbo.com

The point of installing a larger turbo would be to match the INCREASED fuel rate to the air available to burn the increased fuel. One would not invest time and $$$ into a larger turbo if it was not needed. Like buying new tires and not use them.

Even a larger turbo, properly matched to YOUR truck with OUT turning up the fuel will not experience lag beyond what the OEM unit will develop. Quite possibly it could be even better (more responsive) than that of the OEM unit. Depends on what turbo you install and the modifications performed to it/turbinre housing size and type etc.etc.etc.

__________________
1990 D250/1992 D250 Modified by **Smokehouse Diesel** Ashland, OH

....therefore, my brothers, I want you to know that through Jesus the forgiveness of sins is proclaimed to you. Acts 13:38

RIFLEMAN · 02-04-2007, 12:27 AM

Regarding the oil return line, can they be replaced with flexible braided stainless that would be flexible enough to allow for varying angles/lengths of the different turbo applications??

Thanks.

__________________
1985 F-350 w/500,000+ miles
6BT CUMMINS 1st Gen. 1989 Vintage
G360 GETRAG 5-speed
DANA 70 3:55

07-24-2006, 10:25 AM	#1 (permalink)
Dartman48 Newbie Join Date: Mar 2006 Location: Inland Valley, SoCal Posts: 21 Dartman48's Truck Pics	Turbo Changeout - NC Over this past weekend I completed the first of my upgrades. The pyrometer is installed as is the boost gauge. Since I was to have the turbo off and out of the way, I opted to change the compressor housing to a 16cm2. It all went very smooth until I tried to re-attach the oil return from the turbo. There is enough difference in the size of the housing, to change the mounting angle of the pipe flange at the bottom of the turbo and create an attachment problem. The bottom line is, plan on doing an oil filter change when changing the compressor size. I had to remove the oil filter to get to the pipe connector at the oil pan. I shortened the pipe and lengthened the hose to create enough flex in the return line to make a flat fit at the turbo end. Other than fighting with the install until I fugured out what the problem was, it went pretty well, and I'm looking forward to the results. Next is opening up the exhaust system, particularly the down pipe. That's after my arms and back recover from the strain. __________________ Mike 1993 D250 LE, 2WD, Auto, Ext Cab, LB, BHAF, 16cm turbo, stock timing, 3/4 turn on Smoke Screw, ISSPRO gauges.

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07-24-2006, 11:15 AM	#2 (permalink)
BigNorm Cummins Fan Join Date: Jun 2006 Location: Dayton, NV Posts: 59 BigNorm's Truck Pics	crank that injector pump up. You will be impressed! __________________ 93 W250, 5.9L cummins, Auto, 4WD. K&N Air Filter and a strait pipe. Injector Pump tweaked. Timing bumped up 1/8". Home made propane injection and a little bit of grindage on the fuel delivery pin!

07-25-2006, 03:57 AM	#3 (permalink)
Greenleaf First Generation Moderator Join Date: Dec 2005 Location: Ashland Ohio Posts: 806 Greenleaf's Truck Pics	Mike, Allow me to clear up something for you. A compressor housing is the cold (front) housing made of aluminum. The turbine housing is the hot (rear) housing made of cast iron. The exhaust housing is available in the size you described, 16cm2. The compressor housing is the same size physically on your turbo with a small internal difference depending upon the size of the compressor wheel. An example would be 54mm wheel or a 58mm etc.etc. AS far as the turbo drain (return) line and hose assy goes......... The housing size will not have any effect on the return line/angle of the flange etc. I'm not sure what problem you encountered there but it is really odd that you encountered any problem at all. It's possible that the previous owner cobbled a trubo together and you are not working with the OEM parts. GL __________________ 1990 D250/1992 D250 Modified by Smokehouse Diesel Ashland, OH ....therefore, my brothers, I want you to know that through Jesus the forgiveness of sins is proclaimed to you. Acts 13:38

07-25-2006, 08:51 AM	#4 (permalink)
Dartman48 Newbie Join Date: Mar 2006 Location: Inland Valley, SoCal Posts: 21 Dartman48's Truck Pics	You're absolutely right Greenleaf. I got careless with the terminology. I changed out the hot side for the 16cm housing. The compressor stayed stock. As far as the oil return pipe is concerned, it was as stock as can be. The entire truck was bone stock. As I compared the 18cm and the 16cm housings, all I can figure out is that the housing sits just a little bit closer to the manifold because of the smaller diameter. At any rate, it changed the angle of the flange just enough to prevent a flat fit. So the best I could do was mod the pipe a bit. Oh well, it's done now. __________________ Mike 1993 D250 LE, 2WD, Auto, Ext Cab, LB, BHAF, 16cm turbo, stock timing, 3/4 turn on Smoke Screw, ISSPRO gauges.

08-13-2006, 06:57 PM	#5 (permalink)
*Ridemywideglide* Cummins Enthusiast Join Date: Apr 2006 Location: CO. Posts: 260 Ridemywideglide's Truck Pics	I just swapped out my hy35 for an hx40 last night and ran into the same problem as you... Could not get the drain to line up flat.. I loosend the turbine side clamp bolts, and clocked the the compressor around until I got what looked good and flat, then bolted the drain up BEFORE tightening the turbine back down.. That way I know it was flat and won't leak.. This was my first big adventure in diesel-land, and all went well. Today I also swapped injectors... Took 6 hours, had 1 leak (after putting EVERYTHING back together), but now no leaks, and it still runs. But not something I look forward to again.. What size housing did you have on it before? I've noticed a lot of lag with this new turbo, haven't really had it out to run it hard yet, bet the hy35 deffinetly spooled faster... Come to think of it, I didn't look at what size the housing was before I put it on, was too excited.. Where can I find the numbers? Brad __________________ 1996 2500 CTD, Ext Cab SLT Laramie, Longbed 4x4, 225K (rebuilt at 212K), 5 spd, 4:10's, 4 inch lift, 315/75/16's, Max Spool 2, HX40/16, Smokem's 5x012's, No plate, Hacked AFC, Autolite EGT, Boost & Fuel Pressure guages. 2005 WideGlide, Whiskers limited paint, Stage 1, SERT tuned. Soon to be 98"

08-13-2006, 07:42 PM	#6 (permalink)
albacore44 Cummins Fan Join Date: Apr 2006 Location: riverside, california Posts: 80 albacore44's Truck Pics	I also just changed to an S300. Had the same problem with the oil return line. i had to purchae a pipe that fits a 2001 and cut it + add an additional piece of 7/8 hose to spilce 2 pieces of pipe together. big pain but it worked. also I have the spool up problem . the HX-35 spooled quicker. mabee after I break this turbo in it will be better. __________________ 96 Dodge Ram 2500, ATI intake-exhaust,S300 Turbo, 4" exaust , AFE Stage 2 ,Gsk, Custom Plate (Don't know the number, but the truck is fast) , Full Monte DTT, mag hitec pan and diff cover, Snow's stage III water injection, amsoil dual-bypass, filter engineering coolant filter, Dipricol guages (Pyro,boost,trans temp,differential temp,water temp, oil temp,). Amsoil throughout Tows my Weekend Warrior 32' Toy hauler loaded with 3 quads.

10-30-2006, 10:19 AM	#7 (permalink)
bbraden Diesel Head Join Date: Sep 2006 Location: Lubbock, TX Posts: 1,078 bbraden's Truck Pics	I've talked to a lot of people about turbos and from what I gather if you put these bigger turbos on you have to have big horsepower to spin them as fast as the other ones spin. I think this is because it takes more exhaust to spin bigger turbines. I wanted a new turbo but from what I hear I think I'm gonna stick with my stock turbo. I just wanted something that spooled instantly. It doesn't sound like any of these aftermarkets do that. __________________ 99 dodge 4x4 13" Proluk Gold clutch, BHAF-K&N combo, Super X VP44, FASS, Edge comp, MODIFIED Super B Turbo, RV 275's, Quick spool manifold, 4" MBRP straight back, 3.55's, BFG A/T 285's!, somewhere north of 400 hp

10-30-2006, 11:36 AM	#8 (permalink)
Paccool Admin Join Date: Nov 2005 Location: NorCal Posts: 2,366 Paccool's Truck Pics	You second gen guys have the newer style turbos already on your trucks. The 35 is one the first gen guys are going to to help reduce the turbo lag that is present in the first gens with with a stock turbo. Some of the HX-35's are modified for better performance. Go to PDR and look up what they do to the turbos for more info. There are other suppliers out there that also do the mods but I am most familiar with PDR. __________________ Stan 93 D250, PDR Twins HX35&HT3B, 60+# boost,PDR stage 2 head w/o-rings, PDR Cam, modified VE Pump, piston style lift pump, modified 5" intake w/AFE, ATS ported manifold,DTT 89% converter, 4" RIP exhaust, modified tranny, EGT/boost/tranny/tach gauges, TPS removed, a little chrome under the hood. Mag-Hitec tranny and diff. covers. Rear sway bar. Line-x bed liner, after market seats. Front end rebuilt with new springs - 2 " taller now. Single stage Water/Meth system installed. Oversized intercooler w/3" IC lines. 05 Chevy 2500 HD, Duramax W/Allison, 17" Hummer wheels w/285-70-17 BFG's, modified air box, ported turbo mouthpiece. Predator programmer.

11-03-2006, 05:48 AM	#9 (permalink)
Greenleaf First Generation Moderator Join Date: Dec 2005 Location: Ashland Ohio Posts: 806 Greenleaf's Truck Pics	braden, You need to spend some time at the HTT website and read up on turbo options. Educate yourself a little by reading up on what they offer. This would really help you to decide what unit would be correct for your particular application. I'n not sure who gave you the information of the laggy bigger turbo but it's far from the truth unless your simply bolting on an HX40-50 that was pulled from a Cummins "C" This has been done and results is a spool-up time of say, two minutes. __________________ 1990 D250/1992 D250 Modified by Smokehouse Diesel Ashland, OH ....therefore, my brothers, I want you to know that through Jesus the forgiveness of sins is proclaimed to you. Acts 13:38

11-03-2006, 07:23 AM	#10 (permalink)
bbraden Diesel Head Join Date: Sep 2006 Location: Lubbock, TX Posts: 1,078 bbraden's Truck Pics	Oh, I've just been trying to gather miscellaneous info here and there. It's mostly just common sense... bigger turbo on stock setup = turbo lag... what's the address to this website? __________________ 99 dodge 4x4 13" Proluk Gold clutch, BHAF-K&N combo, Super X VP44, FASS, Edge comp, MODIFIED Super B Turbo, RV 275's, Quick spool manifold, 4" MBRP straight back, 3.55's, BFG A/T 285's!, somewhere north of 400 hp

11-03-2006, 10:15 AM	#11 (permalink)
Greenleaf First Generation Moderator Join Date: Dec 2005 Location: Ashland Ohio Posts: 806 Greenleaf's Truck Pics	www.htturbo.com The point of installing a larger turbo would be to match the INCREASED fuel rate to the air available to burn the increased fuel. One would not invest time and $$$ into a larger turbo if it was not needed. Like buying new tires and not use them. Even a larger turbo, properly matched to YOUR truck with OUT turning up the fuel will not experience lag beyond what the OEM unit will develop. Quite possibly it could be even better (more responsive) than that of the OEM unit. Depends on what turbo you install and the modifications performed to it/turbinre housing size and type etc.etc.etc. __________________ 1990 D250/1992 D250 Modified by Smokehouse Diesel Ashland, OH ....therefore, my brothers, I want you to know that through Jesus the forgiveness of sins is proclaimed to you. Acts 13:38

02-04-2007, 12:27 AM	#12 (permalink)
RIFLEMAN Newbie Join Date: Mar 2006 Location: Briar Thicket Posts: 25 RIFLEMAN's Truck Pics	Regarding the oil return line, can they be replaced with flexible braided stainless that would be flexible enough to allow for varying angles/lengths of the different turbo applications?? Thanks. __________________ 1985 F-350 w/500,000+ miles 6BT CUMMINS 1st Gen. 1989 Vintage G360 GETRAG 5-speed DANA 70 3:55