6.7 engine in 2004.5 dodge 3500 dually

[Dalles]

I am trying to install a 2008 6.7 in my 2004.5 3500. Has anyone done this and if so what changes were made. My understanding is the block is the same Can the exhaust brake and turbo be hooked up or do I need to use my old turbo? Can I just take off all the pollution equipment and use my ecm?

 

[cerberusiam]

Yes, strip the 6.7 down to long block condition and use all the 5.9 parts; injectors, rocker box, VC, sensors, exhaust manifold, turbo, ECM, and wiring harness. You will want to retain the 6.7 damper and fan pulley. You will want a grid heater delete for the intake heater and either adapt the 5.9 elbow to the intake or use a pusher intake and an alternate grid heater if desired.

 

[Dalles]

Thanks a lot for your reply I am semi mechanically inclined ( I guess that means not a lot about diesel if you don’t mind putting up with a newbie. My understanding is to get the engine out you have to tilt the cab back to the box. Do you know of any proper videos for that? Thanks Dalles

 

[AH64ID]

The cab shouldn't have to be tilted. The engine can come out the front with the cab in place.

 

[cerberusiam]

You will need to cut the lower radiator support bar and the engine will come out the front easily. Most take the bolts out and slide the support as far one way as possible and one end off so it can be removed. You can either weld it back up if you have a welder or drill new mounting holes.

Makes it much easier of you remove the VC cover, rocker box, turbo and exhaust manifold.

 

[jghflys]

You will need to cut the lower radiator support bar and the engine will come out the front easily.

If you loosen the fender bolts, you do not need to cut the radiator support. You can pry the support out. Here is a quote from sag2 "
The cross member can be removed by removing the bolts (x-member and fender mount) and then CAREFULLY spreading the fenders apart (watch the fender to door contact) and sliding the center section to one side and out the other side. The service manual says cut it on a diagonal and they make a weld repair patch panel." from this thread.
https://www.turbodieselregister.com/threads/pulling-motor-out-any-short-cuts.248272/

 

[Dalles]

Thanks for that info sir. I really appreciate it

 

[Dalles]

i am just wondering why do i need to delete the grid heater? is there no grid heater on a 5.9? and if there is why would i delete it? also if i take the covers off and turbo exhaust manifold and intake do i still need to remove the radiator cross member?

 

[cerberusiam]

The grid heater on a 6.7 is in the intake manifold, not under the air horn. Pull it and you will see why it needs removed after having EGR run thru if for a space of time. It is also an accident waiting to happen with on of the mounting bolts inside the manifold. That bolt is part of the ground and can have the tendency to burn it off and drop it into a cylinder. For all its relative worth, unless you live and drive where temps routinely drop under 0 F delete it.

The other thing you will have to resolve is the MAP sensor location. On a 5.9 it is in the manifold, on a 6.7 it is in the air horn. Ideally you would get grid heater delete that would accept the MAP and the 5.9 air horn and grid heater to make it seamless. Otherwise you may have to extend the existing MAP sensor wiring to mount in the air horn.

The cross member is in the way trying to remove\install the engine at the angle needed. Unless you have a big cherry picker or chain hoist and the ability to demand tilt the engine it gets a little dicey with that much weight that high to clear everything.