Engine/Transmission (1998.5 - 2002) HY-35 Turbo Wastegate Actuator

[madmanmanick]

I have a 2001 CTD with the HY-35. Either the wastegate is stuck shut or the actuator is broken. Can I replace the actuator with one from a hx-35 and use a rubber hose and hose clamps to attach it to the turbo. I figure this might be a cheaper option thatn replacing the entire turbo.

 

[Bob4x4]

The hy is different... ... ... ... . what makes you think your actuator has failed?

 

[blacksheepdiesel]

Aw heck, why not just replace the entire turbo with a bigger one!!!!


Godspeed,
Trent

 

[madmanmanick]

The hy is different... ... ... ... . what makes you think your actuator has failed?

when i step on the throttle the turbo puts out boost of 35 psi on a turbo that should put out no more than 20. 8, then if i am driving and the turbo is producing boost when i let off the pressure stays there and "turbo fart" sound

 

[fox]

I bet it has a boost fooler or a 'box' on it and a turn buckle.

 

[madmanmanick]

I bet it has a boost fooler or a 'box' on it and a turn buckle.

I have yet to make any adjustments of any kind to the turbo

 

[Bob4x4]

Pull the actuator and bench test it



Bob

 

[fox]

Boost fooler keeps the computer from reconizing the extra boost. It 'clips' the signal. What extra fueling does it have?

If it doesn't have any, then I suggest you look at a possible gauge issue.

BTW, a lot of us have run a hy to 35 and never had issues with it.

Does it have a turnbuckle on the wastegate lever?

 

[BLassiter]

just take an air hose and compressor of course and see if its opening when you blow air into it. simple procedure =)

 

[fox]

I have yet to make any adjustments of any kind to the turbo

This and the first post, is confusing me, when it comes from a Cummins Tech.



#1 (permalink)

madmanmanick

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Join Date: Mar 2007

Location: Zion, IL

Posts: 37



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HY-35 Turbo Wastegate Actuator



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I have a 2001 CTD with the HY-35. Either the wastegate is stuck shut or the actuator is broken. Can I replace the actuator with one from a hx-35 and use a rubber hose and hose clamps to attach it to the turbo. I figure this might be a cheaper option thatn replacing the entire turbo.

__________________

Darren M. Manick

Cummins Diesel Tech.

Air Conditioning Tech.



You want to hose clamp a wastegate actuator to the turbo?

Ok, Whay I was getting at is the turbo is set to open wastegate at 20 psi. That IS VERY EASY to check.

The other issue is the computer won't fuel that high unless there is something keeping it from knowint the real boost numbers.

There are HY's for sale, e-bay, the classified adds here, find a cheap one and use the actuator.

 

[JR2]

when i step on the throttle the turbo puts out boost of 35 psi on a turbo that should put out no more than 20. 8, then if i am driving and the turbo is producing boost when i let off the pressure stays there and "turbo fart" sound

Mine used to make 45 psi and that same turbo fart sound..... has this been your truck since new or did you just get it.



i would check the waste gate with air pressure. I used to pull the black hardline off the turbo and tap a . 22 short shell with a very small hole drilled into it in that line. Its a very effective boost elbow for the hy, I know DD used to sell a deal that went in the line that did the same thing.

 

[madmanmanick]

This and the first post, is confusing me, when it comes from a Cummins Tech.



#1 (permalink)

madmanmanick

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Join Date: Mar 2007

Location: Zion, IL

Posts: 37



Photo Gallery



HY-35 Turbo Wastegate Actuator



--------------------------------------------------------------------------------



I have a 2001 CTD with the HY-35. Either the wastegate is stuck shut or the actuator is broken. Can I replace the actuator with one from a hx-35 and use a rubber hose and hose clamps to attach it to the turbo. I figure this might be a cheaper option thatn replacing the entire turbo.

__________________

Darren M. Manick

Cummins Diesel Tech.

Air Conditioning Tech.



You want to hose clamp a wastegate actuator to the turbo?

Ok, Whay I was getting at is the turbo is set to open wastegate at 20 psi. That IS VERY EASY to check.

The other issue is the computer won't fuel that high unless there is something keeping it from knowint the real boost numbers.

There are HY's for sale, e-bay, the classified adds here, find a cheap one and use the actuator.

The configuration of the waste gate actuating line looks very difficult to remove or replace. It looks like it is either press fitted into the turbo compressor housing, or welded to the compressor housing. Now being that I have not been able to find a waste gate actuator for the HY-35 I would like to know if I is possible to use an actuator from a HX-35. In order to install such actuator I would have to cut the metal line and replace it with a rubber hose and hose clamps. Just like the way it is attached on a HX-35. I have installed the Edge Comp chip into the truck, it has a modified elbow with orifice that you are to put into the compressor housing and replace the stock one. I am not able to use that because of the turbo design, so therefore I have not made any modifications to the turbo on my truck. The problem I am having is I am getting 35 PSI out of a stock turbo that is only rated at 20. 8(this does not bother me). The thing that bothers me is I am getting that turbo fart (lacking a more technical term) sound coming from the turbo when I let my foot off the pedal after I have been accelerating. That is what I need help trying to diagnose and fix. And to answer about the Cummins Tech part of my signiture. I am certified as Cummins tech for the 6B5. 9M2, 6BT5. 9M2, 6BTA5. 9M2, and 6BTA5. 9M3. These are all the Cummins Marine Applications which with exception of the block and head and fuel pump are nothing like the Cummins in the Dodge truck.

 

[Bob4x4]

The configuration of the waste gate actuating line looks very difficult to remove or replace. It looks like it is either press fitted into the turbo compressor housing, or welded to the compressor housing. Now being that I have not been able to find a waste gate actuator for the HY-35 I would like to know if I is possible to use an actuator from a HX-35. In order to install such actuator I would have to cut the metal line and replace it with a rubber hose and hose clamps. Just like the way it is attached on a HX-35. I have installed the Edge Comp chip into the truck, it has a modified elbow with orifice that you are to put into the compressor housing and replace the stock one. I am not able to use that because of the turbo design, so therefore I have not made any modifications to the turbo on my truck. The problem I am having is I am getting 35 PSI out of a stock turbo that is only rated at 20. 8(this does not bother me). The thing that bothers me is I am getting that turbo fart (lacking a more technical term) sound coming from the turbo when I let my foot off the pedal after I have been accelerating. That is what I need help trying to diagnose and fix. And to answer about the Cummins Tech part of my signiture. I am certified as Cummins tech for the 6B5. 9M2, 6BT5. 9M2, 6BTA5. 9M2, and 6BTA5. 9M3. These are all the Cummins Marine Applications which with exception of the block and head and fuel pump are nothing like the Cummins in the Dodge truck.

Ok now with the rest of the story... ... ... ... .....

What you are seeing is 100% normal. You have enough fueling to continue to build more boost even with the wastegate open. The HY is not designed to meet the hp you will make with the comp turned up. If you lift rapidly the turbo will "bark" or surge. Get a bigger turbo or learn to drive around the barking.



Bob

 

[JR2]

The black hard line to the waste gate is very easy to remove. There are two bolts on down by the actuator, once you remove them the black hard line slides right out of the turbo. Its been a long time since I did it, but I think there was a big rubber o-ring in there to help it seal up. I have had mine off a few times.

 

[pcarlson]

JR2 is right on as soon as you undo the two bolts the tube pulls right out of the turbo. There is an o-ring seal. I'd be interested to know if there is an retrictor in that tube when you pull it off.



Anything over 26psi on that turbo is defeating its purpose. The air gets to hot even with the intercooler.



Don't bark the turbo to hard as you can break the shaft, its unequal pressures either side of the compressor and the turbine and its not uncommon on fueled trucks when you snap on the throttle and then let off really quick.



Don't let Bob bother you, you'd see the trend when you read his other posts.

 

[darkhorse]

I think you'd be miles ahead if you replaced the Hy with an Hx. You probably could find a good deal on a used on in the classifies of this site.

 

[Bob4x4]

JR2 is right on as soon as you undo the two bolts the tube pulls right out of the turbo. There is an o-ring seal. I'd be interested to know if there is an retrictor in that tube when you pull it off.



Anything over 26psi on that turbo is defeating its purpose. The air gets to hot even with the intercooler.



Don't bark the turbo to hard as you can break the shaft, its unequal pressures either side of the compressor and the turbine and its not uncommon on fueled trucks when you snap on the throttle and then let off really quick.



Don't let Bob bother you, you'd see the trend when you read his other posts.

What??????

 

[jkidd]

I think he confused your conservative realism for being "a stick in the mud"

Bob thanks for all your good advice and reason.

 

[AKAMAC]

JR2 is right on as soon as you undo the two bolts the tube pulls right out of the turbo. There is an o-ring seal. I'd be interested to know if there is an retrictor in that tube when you pull it off.



Anything over 26psi on that turbo is defeating its purpose. The air gets to hot even with the intercooler.



Don't bark the turbo to hard as you can break the shaft, its unequal pressures either side of the compressor and the turbine and its not uncommon on fueled trucks when you snap on the throttle and then let off really quick.



Don't let Bob bother you, you'd see the trend when you read his other posts.

pcarlson, I'm with Bob on this one. There are two 10mm nuts to loosen and a circlip to remove to pull the actuator for testing.

His description of the HY over-boosting with a box and tap are well known.

Maybe you have him confused with another Bob.

Mike

 

[madmanmanick]

does anybody know where I can find a new actuator for this turbo since I geuss it is changeable?