'05 Turbo on early '04

[Briman]

I have an early '04, 305 HP. Its turbo peaks at around 22 psi of boost. I would like an inexpensive way to add an extra 10 psi of boost. I think the later '04 and '05 had a different turbo. Does it allow for higher boost? Can I retrofit it to my early '04? I ask because I can pick one up for a lot less than an II or HT. I have a banks exhaust and don’t use the stock cast exhaust elbow. I think the turbo flange for the exhaust elbow is the same between the two revisions. What about '06, '07?

 

[EDankievitch]

Waste gate on the 05 and newer is computer controlled, also elbo is larger to meet up with the 4" down pipe... ...

 

[Briman]

As I said, I don't use the elbow, so if the flange on the turbo where the elbow mounts is the same, it's good. So how do I deal with the electronic waste gate?

 

[kblranch]

ATS makes a plug that takes the place of the computer controlled waste gate solenoid. Its like $40. 00 for the plug and the three o rings. Then you need to drill and tap the turbo to install a line to the waste gate like your 2004 has.

 

[CToney]

I am in the process of doing the same swap. Since you have the banks exhaust your swap is easier. The newer turbos are good to 30 psi instead of 26. I can see 26 psi on my truck. With your Bullydog you should see that as well I would imagine. I see you have a fuel pressure guage so you should have fuel. You might have another problem as to not 26 psi. The newer turbos sell for ~$300. I am putting on an ATS manifold and full 4" when I do the swap.

 

[TCDiesel]

The 03/04s are capable of producing 35/40psi with elbow (compressor) and or actuator. No need to change Turbo.

 

[Briman]

CToney, I can get 26 psi. EGT gets quite hot though. I read somewhere that over 22 psi is taking the turbo out of its "MAP". I was hoping the newer turbo would be cooler at higher psi. I am changing the exhaust manifold and would like to do both items at the same time. I can't afford a SPS 62 so I thought this would be a fun experiment. I will check with ATS for the plug and seals. I'm also going to call TWest and see what he has to say about changing the turbo I have to produce more boost. Thanks for all the replies.

 

[cerberusiam]

The 03/04s are capable of producing 35/40psi with elbow (compressor) and or actuator. No need to change Turbo.

They make that much but they don't like to, the difference from the HE341 to the HE351. The 351 will cool a lot better at 30-37 psi and work decent up to 45 psi.

 

[CToney]

Briman my egts never get too hot with the JR. I have had them get to 1300F on a long hill with the trailer on. This is part of the reason to do the swap in the summer I would definitely get hotter than 1300. I like doing a little wrenching so this is an inexpensive way to improve things and gain a little MPG.

 

[Shifter]

The "computer control" on the 05 - 06 turbo is just a pwm solenoid valve that bypasses compressed air back into the inlet of the turbo for much, much better spooling. This will work good to about 40 psi, but realize it's not that much more air. The small exhaust wheel and housing, which is the same as the 03-04 turbo, restricts the exhaust to raise intake pressure. If you do nothing with the wire on the valve, the turbo will spool slower than the original. I found that putting a pressure switch connected to the intake (normally closed) with 12 volts to the vlave, will spool the turbo very well. The idea is to give the valve 12 volts up until you reach the setpoint in boost pressure and remove the 12 volts for any boost above your pressure switch setting. 40 is good, 45 is better but you need a fast pressure switch to prevent overspeed, above 50 will leave your turbo in parts. The benefit of this turbo is the larger intake wheel and housing. Nice for an extra 25-75 hp. Not enough for an extra 100 hp.



The 03-04 turbo holds up pretty well to about 30 psi.

 

[kblranch]

Piers recommends that the 03/04 turbos are only effective/good to 32 PSI. Anything above that is just hot air.