Need Help With Some Measurements Turbo to Firewall

[CrewCabDiesel]

Hope you all can help, I am in the middle of a turbo install nightmare and not sure if I am being told truth. I have been told by BD Diesel that there is a difference in firewall clearances on the 3rd gens and that is why my new Super B will not fit. Right now I am out 2 days of labor, and a $600 in profit run, and the truck is STILL down!:{:{
So could as many of you with a 2003 to 2006 truck please measure from the rear turbo mounting bolt to the firewall on a level plain (up to the heat shield is fine) and post below the year truck, distance between the rear bolt and firewall, type of turbo, type of manifold, trans type.
Also anyone out there with a Super B turbo in a 2003 to early 2004 truck please chime in. I would love to hear how it fit and could you send some pictures!
thanks
Kyle

 

[JJPage]

I just posted pics on your other thread, of my 03 with a Super B. BD sent you the wrong turbo, or at the very least, the wrong turbine housing for your application. Whomever at BD, spun you the tale about differences in firewall clearances between same year trucks, is full of it! Jess

 

[cerberusiam]

Whomever at BD, spun you the tale about differences in firewall clearances between same year trucks, is full of it!

Yep, another BD excuse for screwing things up.

 

[JJPage]

The turbo BD sent you, may have worked with their center dump exhaust manifold, but not with the OEM manifold.

 

[B.G. Smith]

06 3500 quad, auto Sport. I can get 8 1/2" from the center of the rear bolt to the heat shield. This is the stock manifold which exhausts between cylinders 4 and 5. Turbo is what came on it new. bg

 

[CrewCabDiesel]

I think they are giving me a line too, but if I can prove its BS then I can do something about it. I think my best option is contact BD Tuesday (Monday is a holiday in Canada) and insist on talking to upper management, but I have to have some proof so PLEASE keep the data coming. I am NOT going to install a super b special, I need a truck that I can work FIRST!
Thanks
Kyle

 

[rscurtis]

I have this setup on my truck, and had to shorten the engine pipe about 2" to get the exhaust system to sit in the center of the hangers. However, when I was at Carlisle yesterday, I was talking to Dale Zimmerman (Zimmey's Automotive in Lebanon PA), and he told me that the Super B is now an exact replacement. It no longer requires the exhaust adapter or the discharge elbow on the compressor housing. Failing that, you may want to get the latest version of the Super B, and I would recommend their manifold also. Regarding clearance, the downpipe clamp almost touches the firewall insulation, but with the EGT's my truck runs, I'm not the least bit concerned about it. If you want some photos, let me know and I'll take some today. My original pictures are on the old Dell and I haven't moved them.

 

[CrewCabDiesel]

Rscurtis, thanks for the info, if you have please post those pictures.
I have posted some pictures of the turbo that BD sent me, notice the size difference and distance between manifold to rear of housing. Also can anyone id this turbo I now am not sure what it is anymore. I also noticed a build date of November 2007 stamped on the exhaust housing, interesting?
thanks
Kyle

 

[CrewCabDiesel]

This is a picture of the two turbos setting next to each other, see any difference

 

[p-Bar]

Be sure when you talk to them that you tell them that you have posted this on TDR and you would like to post a happy ending and they need to step up to the plate.

 

[rscurtis]

Here are some photos that I hope will be helpful. If you can, I would try to upgrade to the latest design, your life will be much better for having done so. Note that the downpipe clamp is just about to touch the insulation. It's been like that for 3-1/2 years with no ill effects. The hardest part of the job was removing the engine pipe from the muffler pipe- when the truck is assembled, no consideration was given to the poor schlub who may want to take it apart again. What I did with mine is hang the turbo on the rear half of the manifold, bolt it to the engine to position it, and clock the center section so that the oil drain lines are aligned. Next, clock the compressor housing for proper clearance on the discharge elbow. Then, remove everything and tighten all the turbo housing bolts.

 

[rscurtis]

While you're at it, set the boost while you have the turbo on the bench. It comes from BD set at 45 psi. I lowered mine to 26 psi, which is just where the stocker would relax the waste gate.

 

[JJPage]

rs



Your exhaust housing appears to have a longer discharge than mine does also, can you measure it's length? You also have what appears to be a center dump manifold, which accommodates the longer housing?



Here's a pic of mine, inserting the tape into the deepest part of the groove on the rear of the housing nets 2 1/8" to front of v-band.

 

[CrewCabDiesel]

I have a standard 3rd gen exhaust manifold
Measurements from exhaust housing like you measured is 2 1/2"
housing thickness is 5 1/8" (from outlet end to where it bolts to bearing center piece).
I called BD, Everyone is out for the Canada holiday, owner is out until next week.
I am wait for a call from Chris and Cam tomorrow, is Chris someone to deal with? supposed to be a manager ?
I did cancel the Super B special shipment
How would a Killer B work on my truck?

Thanks
Kyle

 

[JJPage]

I don't know anyone personally who has run one. They are a 63 comp / 65 turbine, I believe a 14cm housing. Pretty close to a PhatShaft 62 (62/65), which was my first turbo upgrade and it worked great for towing and all around daily driving. I also ran a SuperPhatShaft 62 (62/71) another nice charger in it's day, but it didn't hold up to my fueling. Then I made the mistake of a Silver 62 (62/74), lousy for any kind of towing, Hence our position on the Super B Special...

The issue I would want to be sure about up front, is fitment with your oem exhaust manifold, and BD's assurance it will fit... you have already been their victim once, it would appear.

 

[rscurtis]

I checked my measurement and it's the same as yours. I have the BD manifold that replaces the stocker. The outlet is in the same location and it's a much better piece than the OEM part, as the last two cylinders do not share a port like they do on the stocker. The third photo shows the turbo on the rear half of the manifold- the front half is just a runner that feeds the rear half. If you're using the stock manifold, you're only doing half the job, IMO.

AFAIK, the Killer is made for the "600" engine. The "special" is for even more power. If you are at stock fueling like I am, the Super is the one you want. Once you get through the installation, you'll be happy with it, and see a FE benefit also.

 

[AH64ID]

This is a picture of the two turbos setting next to each other, see any difference View attachment 86117

That does not appear to be a 3rd gen turbo, the turbine housing is defiantly too long.

 

[JJPage]

This here would be an excellent turbo for you.
http://www.competitiondiesel.com/forums/showthread.php?t=157627

 

[CrewCabDiesel]

BD is shipping a Killer B, should be here tomorrow, let you all know how things go

 

[AH64ID]

That will be a better choice than the Special.