Attention: TDR Forum Junkies 
CharlesHoward
TDR MEMBER
THREE OR FOUR STARS?
FYI
Over a year ago at 158K miles on my 05 I ignorantly let my local shop install new Exhaust Manifold (EM) GASKETs as some were failing/leaking. Versus thinking it through and getting a new EM then, albeit it would have cost a little more.
Exhaust Smoking issues arose this summer and Boost fell off so I decided to purchase / patronize a TDR vendor and purchased a BD IronHorn SXE361/SXE76 Turbo Kit through "Thoroughbred Diesel" to "refresh" and possibly slightly improve towing performance. I'm often influenced by advertising to my wife's chagrin...Many TDR on articles over the years on such upgrades were also influential.
- Maybe my OEM Turbo solenoid was bad, but it is still free-wheeling and not sloppy...
Earlier this month I began the IronHorn install by removing the OEM EM and Turbo, Battery, and also added a "cool hose" to the Airbox. That was not bad. Single hardest chore was reaching the Turbo Drain Hose bolts through the frame. Also, I could not separate the Turbo from the EM on the Truck (Back Bolts were TIGHT), but could on the "ground". I did not need to remove the front Tire/Wheel and fender wheel as the instructions suggest, but it would have made some of it easier (or access to a Lift). I spent a lot of time on my back and I should have at least lifted the RAM front end a few inches on some blocks - fortunately I'm skinny...
However Installing the BD IronHorn was more difficult than expected and beyond complete DITY (in my driveway).
I purchased Studs so the EM and Turbo could be installed/ hung on the engine as together as one and that is definitely a TWO man job. But it fit easily! And all other connections went well except as noted:
I also replaced all the "Turbo/air" hoses with "Mr Bob's" Silicone Hoses.
So I was not able to completely install it myself and probably saved only a few hundred dollars (for removal and most of the installation) after paying the Shop for the Exhaust and Bolt redo…
Ram ran fine and no codes! Wife did not notice smoke (but more driving will tell the tale...)
But now is dead due to my failed Fuel Filter change...I still wonder how that went wrong.
FYI
Over a year ago at 158K miles on my 05 I ignorantly let my local shop install new Exhaust Manifold (EM) GASKETs as some were failing/leaking. Versus thinking it through and getting a new EM then, albeit it would have cost a little more.
Exhaust Smoking issues arose this summer and Boost fell off so I decided to purchase / patronize a TDR vendor and purchased a BD IronHorn SXE361/SXE76 Turbo Kit through "Thoroughbred Diesel" to "refresh" and possibly slightly improve towing performance. I'm often influenced by advertising to my wife's chagrin...Many TDR on articles over the years on such upgrades were also influential.
- Maybe my OEM Turbo solenoid was bad, but it is still free-wheeling and not sloppy...
Earlier this month I began the IronHorn install by removing the OEM EM and Turbo, Battery, and also added a "cool hose" to the Airbox. That was not bad. Single hardest chore was reaching the Turbo Drain Hose bolts through the frame. Also, I could not separate the Turbo from the EM on the Truck (Back Bolts were TIGHT), but could on the "ground". I did not need to remove the front Tire/Wheel and fender wheel as the instructions suggest, but it would have made some of it easier (or access to a Lift). I spent a lot of time on my back and I should have at least lifted the RAM front end a few inches on some blocks - fortunately I'm skinny...
However Installing the BD IronHorn was more difficult than expected and beyond complete DITY (in my driveway).
I purchased Studs so the EM and Turbo could be installed/ hung on the engine as together as one and that is definitely a TWO man job. But it fit easily! And all other connections went well except as noted:
- MAJOR Disappointment was the provided Turbo Downpipe did NOT reach the Exhaust Downpipe. The Turbo Downpipe was at least 1” away and appeared shorter than the OEM Downpipe. That really surprised me! My efforts to loosen the exhaust and jack and stretch it were unsuccessful. My repair shop charged me $499 in labor to bend, heat, move the Exhaust system to reach/fit. Perhaps I should have gone to an exhaust shop and let them put an extension or cut and put a Flex joint on… Didn’t know any better as I assumed being on a LIFT my shop could readily (versus extensively) adjust the Exhaust to fit.
- Also, since the EM instructions had a M10 hex head socket bolt for the Heater Hose bracket but the IronHorn instructions said to use one of the provided short bolts, I first tried to install the M10 Hex bolt with a Hex Socket on an extension but could NOT get it to go in. After loosening the EM I mistakenly assumed I could just use one of my long aftermarket studs (easier to hang/install the Kit on the Engine) would work (also long bolt easier to reach the Head Block) – it did go in but Nut would not work due to clearance…(as I later learned). My mistake…. My Shop spent lot of effort to remove that bolt and said a LONG Hex head key was needed to fit and fasten the Hex bolt (a tool not suggested in the instructions). Perhaps the IronHorn Instructions short bolt is the way to go...
- I didn't manage to bend the Flex Turbo Oil Drain correctly enough or have enough strength to push it all the way into the block so my Shop had to fix that for me...
I also replaced all the "Turbo/air" hoses with "Mr Bob's" Silicone Hoses.
So I was not able to completely install it myself and probably saved only a few hundred dollars (for removal and most of the installation) after paying the Shop for the Exhaust and Bolt redo…
Ram ran fine and no codes! Wife did not notice smoke (but more driving will tell the tale...)
But now is dead due to my failed Fuel Filter change...I still wonder how that went wrong.
