VGT swap onto a 2nd gen 24 Valve - Dodge Cummins Diesel Forum
Articles - Engine, Core Heavy duty, high definition engine topics

LinkBack Thread Tools Display Modes
post #1 of 2 (permalink) Old 11-18-2010, 02:24 PM Thread Starter
SC Chapter President
carolinarednek's Avatar
Join Date: Jun 2007
Location: Liberty, S.C.
Posts: 1,289
Thanks: 10
Thanked 36 Times in 21 Posts
iTrader Score: 0 reviews
VGT swap onto a 2nd gen 24 Valve

So, you have decided to do this swap. After reading all of the write ups and all the advantages and disadvantages of the turbos, we decided to do one.

Things you will need:

1. Another vehicle to drive while you do all the fab work!! It took me about a week to do this swap and fab work.

2. Exhaust Manifold and turbo from a 6.7 Cummins. Manifold MUST be from a 6.7 Cummins. The turbo flange is different from all the other flanges from 1st, 2nd, and 3rd gen trucks.

3. A controller from Fleece Performance to control the turbo.

4. A STOCK down pipe from a 3rd Gen truck.

First things first, disconnect the battery cables!!! Then begin removing the stock turbo and exhaust manifold.

(You can recoup some of you cost on this swap by selling you stock manifold to someone with a 3rd gen.) If your truck is an Automatic, you will have to either relocate the tranny cooler or bypass it and remove it. We opted to remove our cooler and reroute the tranny lines. If it's a Manual truck, don't worry about the cooler.

Now begins the fun part. Fabrication!! Start by installing your new manifold onto the truck. You might find it is easier to have the turbo already bolted up to the manifold as it can be a rather tight fit to try and put it on after putting the manifold on.

Make sure to route coolant lines to the turbo. If you do not have coolant going to the turbo, you can possibly cook the electronics in the turbo.

We used a flexible turbo drain on ours since the stock one from the truck wouldn't work. We removed the freeze plug closest to the rear of the engine just above the oil pan. Take special care to make sure you don't accidentally knock it into the engine. We took a long screwdriver and a hammer and tapped on one side of it till it started to "spin" in the hole. After that, we pulled it out using a good pair of pliers. If you want to, you can reuse that freeze plug and install it into the already open turbo drain hole, or use some other method of blocking off that hole. To fabricate the piping going to the Inter cooler, we used 3" exhaust piping, and swelled one end of it to fit the stock boot going to the Inter cooler.

Install the exhaust elbow onto the new turbo, and then turn it to where your down pipe will mate up to it. If you already have 4" exhaust, you'll be in good shape. If not, now's the time to upgrade to 4" or go buy an adapter to reduce from 4" to 3" if you still have the stock exhaust on your truck.

All that's left now is to hook up all the connections for the controller. Make sure to keep all loose wires tied up out of the way. Mount the controller under the hood somewhere and mount the knob to control the vanes in the turbo, and the switch to turn the exhaust brake on and off.

And that's it! Sounds simple enough, but like I said before, it took a week of fabrication to get everything hooked up and in working order.

Here's a small video so you can hear the turbo screaming while playing with the knob for the controller. Kinda sounds like a jet engine!!

1996 Dually 4X4
Transmission by Pro Street Diesel (Darren is the man!!)
Tuning by Cox Diesel Performance (864)991-9263

395hp/867tq on Dunbar's Dyno @ 40psi 7/10/10

To view links or images in signatures your post count must be 3 or greater. You currently have 0 posts.

Last edited by carolinarednek; 11-20-2010 at 09:28 PM. Reason: Added pictures and video
carolinarednek is offline  
The Following 13 Users Say Thank You to carolinarednek For This Useful Post:
Arkadios (04-18-2013), bigmurph68 (01-24-2013), bleedcummins (02-15-2011), cummins04.5handshaker (02-25-2011), cumminsproud (01-18-2011), D-McCummins (07-14-2011), dcraig4570 (08-16-2011), DodgeMech (02-08-2011), Gasoline Sucks (03-17-2011), jk1211 (03-01-2011), rwhite1 (01-29-2011), sled head (01-23-2011), Spunkys Ram (01-04-2011)
Sponsored Links
post #2 of 2 (permalink) Old 01-07-2013, 08:12 PM
VP Moderator
dozer12216's Avatar
Join Date: Dec 2008
Posts: 11,953
Thanks: 1,732
Thanked 1,647 Times in 1,403 Posts
iTrader Score: 0 reviews
And what is the performance improvement quotion??

2008 3500 stock QCLB dually Inferno red. Toys: Fuel injected Rampage
To view links or images in signatures your post count must be 3 or greater. You currently have 0 posts.
, Road Grader, 1586 tractor, 60K genset, Honda ATV, and more. Back in business with a Hitachi EX270LC excavator. The dirt slinging has begun with 50+ acres to clear.

To view links or images in signatures your post count must be 3 or greater. You currently have 0 posts.

To view links or images in signatures your post count must be 3 or greater. You currently have 0 posts.
dozer12216 is offline  
Sponsored Links
Closed Thread

Quick Reply

Register Now

In order to be able to post messages on the Dodge Cummins Diesel Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.

Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode

Posting Rules  
You may not post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome