Any tips on installing a new Garrett Powermax Turbocharger Stage 2 GT3782R?

[Motorhead]

When I did my COOLING system flush, I ordered a full set of BOB'S Silicone hoses. When I went to replace the boost hoses, I discovered that my turbo was pushing a small amount of oil from the compressor outlet side of the turbo. Went to Dodge under warranty and "of course", "Well that is sometimes normal" and "You know, you have a non approved exhaust brake" (Pac-Brake). So needless to say, at 60,000 miles on the truck, they refused to replace the turbo under warranty!
I checked the price on a NEW stock turbo and they want about $1385.00. For $1775, I contacted Turbo Resource and bought a brand new GARRETT Powermax stage 2, GT3782R, Dual Ball Bearing Turbocharger Kit.
Tom and Jay at Turbo Resourse couldn't be a nicer set of guys for explaining and offering great service and excellent building of turbos. Their price was a lot less than others I looked up on the web. I bought one of the last 3 kits Turbo Resource has as Garrett isn't putting together anymore of these kits due to slow demand. (If you're thinking about it, you better not delay much longer.)

SO.... I am getting ready to install it in the next few days and wanted to ask anyone who has "Gone before me", installed the kit and found a tip or two of things to look for.
Also, How much coolant did you lose and have to replace?
I plan to remove the right front wheel and inner fender well if you think that makes it any easier. Any tips welcome!

 

[Prairie Dog]

I can't help you but I would sure like to hear your impressions of the new turbo after you install it since you just have a SmJr like myself.

 

[seafish]

AH64ID has done the exact turbo install on his truck and loves it.

https://www.turbodieselregister.com/threads/229555-Garrett-Powermax-Stage-2-GT3782R-Install-Review

 

[Motorhead]

AH64ID, I think has an aftermarket cam too. I have been thinking eventually going that way too to get rid of the EGR cam.

 

[lpennock]

One of the flange bolts is a real pain to get at. Don't remember which one for sure but I think it was front engine side. Put the hose on the rear cooling pipe of the turbo before you install the turbo then you can slide it down to put it on the other line. You want to use spring clamps rather than screw clamps on the heater hoses or you will get some dripping when things get cold. I seem to remember it would be easier to put front cooling line after mounting turbo. Make sure rear line is fully torked on bench as it is a ***** to get at on the truck.

 

[Joseph Donnelly]

Snap-on makes a 15 mm open end wrench with offset angles on each end, makes it easier to tighten the mounting nuts that are partially covered by the turbine housing scroll on many aftermarket turbos.

 

[Motorhead]

One of the flange bolts is a real pain to get at. Don't remember which one for sure but I think it was front engine side. Put the hose on the rear cooling pipe of the turbo before you install the turbo then you can slide it down to put it on the other line. You want to use spring clamps rather than screw clamps on the heater hoses or you will get some dripping when things get cold. I seem to remember it would be easier to put front cooling line after mounting turbo. Make sure rear line is fully torked on bench as it is a ***** to get at on the truck.

Where do you get the additional spring type clamps?

 

[lpennock]

Autozone, O'Reilly, NAPA

 

[seafish]

Bob at Mr. Bobs can also get them for you. He sent me extra silicone hose and extra silicone type hose clamps for me to install a coolant filter on my truck.

 

[Shadrach]

I have the same turbo on my 03, and a few other similar goodies I see. It has lower boost when driving "normal" but goes up fast and goes higher than before when your foot is into it, like when towing. It " sings " compared to the stock one. The only draw back, and it is minor, is that it takes a little longer for the EGT's to cool down if you have to pull over and stop in a hurray. I had trouble with the outer coolant pipe fitting and ended up doing it my way. Over all I like the turbo. David

 

[Motorhead]

I called Tom today to ask a question as to where he sets the waste gate pressure to. He sets them to open at 38 psi. He also says to NOT install the factory waste gate electrical valve into the turbo. He says to hook it up electrically by plugging it into the trucks wiring and hang it somewhere out of the way and leave the turbo "Mechanically" waste gate controlled.
SHADRACH, you have a picture of how you had to change the outer coolant pipe? My kit has THREE coolant pipes! One is almost bent into a square. I asked Tom about that and he said it must be for another application as I also had a turbo drain pipe too in the kit. My understanding is that I am to use the drain that the stock turbo uses.

 

[lpennock]

06-07 uses the straight coolent lines. The bent one is for older trucks. I used the drain line that came with the kit.