Anyone have problems with DD HX40 downpipes?

[work2muchplay2little]

Been installing stuff like a maniac today. Attached the HX40 to the exhaust manifold, climbed underneath to check the alignment of the downpipe and the tail end of the down pipe is pointing at the driver's side rear corner. No way the next piece is gonna fit. Both the HX40 and downpipe are from DD. Anyone else seen this? Any solution besides waiting another couple of days next week to get a new one?

BTW, the wastegate is welded shut, no actuator, on their prep of the HX40.

TIA

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Kurt Voss
********* 1999 2500 24VCTD AUTO 4x4 QC LB Laramie SLT, Luverne stainless steel nerf bars, 3 piece bug deflector, mopar mud flaps, Line-X bedliner, Blue Chip Fuel Management System (Premium), Psychotty Air, DD3's. To be installed next week (4/7/01) TTPM, DD 4" exhaust, HX40, DTT VB/TC(91%) , Mag-Hytec transmission pan... YEEEEEHAAAA!!

 

[Blkdawdg]

My doesn't fit well either. Where the HX-40 and the downpipe fit together, I have about a 1/4" gap on one side. I didn't really think that there was much that I could do so I just left it.

 

[BIG BOB]

I installed mine today. Same problem, the bends were wrong. After completely disassembling my entire exhaust and 3 1/2 hours later, still could not get it on.

I was a little upset, to say the least. After much evaulation, I finally decided I need a 4" slip joint. At 3:30 Saturday afternoon I called several muffler shops (most were closed) nobody had any 4" material or equipment, I finally called the Napa main store in Spokane, they had one. So at 4:15 I drove into Spokane and picked it up. Upon returning home I took the downpipe and cut the slip joint into it. It worked great! I was able to turn the downpipe to the exact position I needed to reassemble the exhaust system.

You would think that with as much experience that DD has, that these pipe would fit.

I think that Stan's Headers make a 2 piece pipe, that would eliminate the problem. Maybe DD should do the same.

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[This message has been edited by BIG BOB (edited 04-08-2001). ]

 

[work2muchplay2little]

Big Bob,
how does a slip joint work? Do you cut the downpipe in 2 pieces and put the slip joint in between to allow some rotation? If so, what did you use to cut the pipe with? At present, my first section after the downpipe is a little skewed, but, I really like the HX40!

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Kurt Voss
********* 1999 2500 24VCTD AUTO 4x4 QC LB Laramie SLT, Luverne stainless steel nerf bars, 3 piece bug deflector, mopar mud flaps, Line-X bedliner, Blue Chip Fuel Management System (Premium), Psychotty Air, DD3's. To be installed next week (4/7/01) TTPM, DD 4" exhaust, HX40, DTT VB/TC(91%) , Mag-Hytec transmission pan... YEEEEEHAAAA!!

 

[Vaman]

I went through this same thing... drove with just my downpipe for a week. Part of the problem is even if you get the thing in, you'll be stressing the sh*t out of your turbo housing. I ended up grinding the midpipe to an angle to fit the angle of the downpipe and using a flexible bandclamp to complete the butt joint. No stresses. As far as the HX-40, it also comes in a NON-wastegated version... that might be what you have. Best of luck.

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98. 5 2500, 24v, 5 speed, QC, 4x4, 4. 10 LSD, short bed, Line-X liner, tow package, camper suspension, Westin nerfs, camper shell, TST PowerMax Competition, 275 RVs, Psychotty air, HX-40, 4" straight pipe exhaust, ProComp A/T 305/70/R16s, EGT/Boost pillar gauges... Love my Cummins, no love for Dodge

 

[Arcticat]

What total Bull$hit! I keep hearing about how great DD is, but come on, exhaust work is not rocket science, and after selling lots of HX40's at $1200 a pop for a truck that hasn't changed bodywise in seven years, they should be able to bend a piece of pipe that fits. I sure hope the Stans downpipe I ordered goes in better. He told me it was a two pice design, to avoid just the problem you guys are having. It better work... . if not you guys will be the second to hear about it - after I get off the phone. Good luck guys, it sounds like your ingenuity has solved the problem, in spite of DD's shortcomings.

 

[Archive]

Here is a thread I found working the midshift the other night, from the 12 valve forum. . https://www.turbodieselregister.com/ubb//Forum1/HTML/003654.html

Sounds like a nice thing to me. . big enough turbo to cool things down, still able to use an exhaust brake at the elbow, and your stock or upgraded downpipe.

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Rob Hanson
1999 "Big Red", 3500 SLT QC 4X4 6 spd, 4. 10 LSD, Braided SS fuel lines, Mag-Hytec Rear Cover, Cummins E-Brake with BD Switch, Blue Box, DD3 Injectors, Banks High Ram and 14cm Wastegated Turbo, All-steel Cowl Induction Hood, Cummins RED Valve Cover, Rhino, Rosewood Kit, Scotty System, SportComp Gauges, TorkLift SuperHitch, Tekonsha Brake Controller, Rear Flood lights, Cobra CB, DeeZee Running Boards, BD 2WD Low kit, Air Lift bags, Hitco exhaust blanket, air horns and a Geno's "I tromped a Ford" decal. Member of BOMB! (WW NW Chapter)

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I'd rather be... .
Cummin than Strokin.

 

[Arcticat]

Hemi, I think he means DD welded his wastegate shut. If that's the case I find that sort of bizarre, since it's been discussed over and over again here that the HX40 can break shafts at higher boost, and DD should know that.

I was also curious what benefits one would see with header wrap on the downpipe?

FYI anybody who is considering getting an HX40 sportbike sets them up with their own actuator, no tinkering with your existing actuator to get the new turbo and wastegate to work. That means your old HX35 just unbolts as a complete unit and could be used on another truck if you wanted to sel it to one of the guys that has an HY35. I noticed recently that BD is selling HX35-12cm's for 1000 bucks #ad
#ad

 

[work2muchplay2little]

Just to clarify; there is a lever arm protruding from the turbine housing that has a hole in it that looks to be for a linkage connection point. This lever arm is tack welded to the turbine housing. As this is the general location of the wastegate linkage on the stock turbo, and there is no actuator, I'm making an assumption that it is for the wastegate. Please correct me if I'm wrong.

I'm going to call DD in the morning and discuss this with them as well as the downpipe problem. I will post the results of my conversation. Would much prefer to have a correctly configured downpipe than to have to modify a brand new one... .

Thanks guys for the input.

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Kurt Voss
********* 1999 2500 24VCTD AUTO 4x4 QC LB Laramie SLT, Luverne stainless steel nerf bars, 3 piece bug deflector, mopar mud flaps, Line-X bedliner, Blue Chip Fuel Management System (Premium), Psychotty Air, DD3's. To be installed next week (4/7/01) TTPM, DD 4" exhaust, HX40, DTT VB/TC(91%) , Mag-Hytec transmission pan... YEEEEEHAAAA!!

 

[HEMI®Dart]

work2muchplay2little,

Find out about the wastegate. This sounds strange. I was under the impression DD sells the BD prepped HX-40 Kits. Piers would never weld the wastegate shut.

[This message has been edited by HEMI®Dart (edited 04-08-2001). ]

 

[BIG BOB]

work2muchplay2little
I purchased a slip joint from Napa with 2 - 4" clamps for $22. 00. I layed the downpipe on its side and the slip joint next to it, marked the length of the slip joint on the downpipe along with the length the downpipe would slip into the slip joint. I then used a sawsall and cut the downpipe to the length it slips into the slip joint. Filed the edges of the downpipe after cutting and presto change-o, I now had a downpipe that worked great.

The HX-40 I got from Majestic has a wastegate and has not be modified by them.

I get my South Bend clutch in tomorrow, I'll let you know about boost and EGT's after that.

 

[EMDDIESEL]

I give up, What is the "HX-40" and who is or what does "Majestic" do?

 

[work2muchplay2little]

Originally posted by EMDDIESEL:
I give up, What is the "HX-40" and who is or what does "Majestic" do?

EMDDIESEL, the HX-40 is the larger turbo that comes standard on the Cummins C engine, an 8. 3L. This is used on our engines to increase boost and better manage EGT's that are created by adding lots of extra fuel with larger injectors and fueling boxes #ad
. Majestic is a company that does turbo modifications to decrease spool up time among other things (if your considering this read the thread about HX40/Majestic blues). Hope this helps.

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Kurt Voss
********* 1999 2500 24VCTD AUTO 4x4 QC LB Laramie SLT, Luverne stainless steel nerf bars, 3 piece bug deflector, mopar mud flaps, Line-X bedliner, Blue Chip Fuel Management System (Premium), Psychotty Air, DD3's. To be installed next week (4/7/01) TTPM, DD 4" exhaust, HX40, DTT VB/TC(91%) , Mag-Hytec transmission pan... YEEEEEHAAAA!!

 

[HEMI®Dart]

work2muchplay2little,

I don't like the idea of Majestic welding the wastegate shut. These turbos can break a shaft at about 50 psi boost. Piers told me to set the wastegate to dump boost at 40psi. Be careful. The Piers prepped 40 has the wastegate linkage reconfigured to hook right up to the OE actuator.

I have planned ahead for downpipe probelms. 2 feet of flexpipe, 2 band clamps and a Sawzall will be on hand. I have a BD downpipe. Have not fitted it yet. I will need to hook it up into an exsisting 4" exhaust. This is where a problems could start. The DD & BD downpipes should be the same thing. I wonder why there are problems?

IMO everybody should be wrapping the downpipe with header wrap too.

[This message has been edited by HEMI®Dart (edited 04-08-2001). ]

 

[work2muchplay2little]

I spoke to DD this morning. First of all their customer service is good. They acknowledged that they had had several downpipes that were built wrong. They offered to cut, rotate, and reweld a new one and send it at no additional cost. Bingo, just what I need.

Regarding the HX-40 welded wastegate. They said that they do them all that way and have never had a problem. Highest boost I've seen so far is 40psi. I'll let it be for the time being and monitor the boost pressures.

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Kurt Voss
********* 1999 2500 24VCTD AUTO 4x4 QC LB Laramie SLT, Luverne stainless steel nerf bars, 3 piece bug deflector, mopar mud flaps, Line-X bedliner, Blue Chip Fuel Management System (Premium), Psychotty Air, DD3's. To be installed next week (4/7/01) TTPM, DD 4" exhaust, HX40, DTT VB/TC(91%) , Mag-Hytec transmission pan... YEEEEEHAAAA!!

 

[EMDDIESEL]

Thanks for the info, how much does one of those turbo's cost (Estimate)?

 

[work2muchplay2little]

Originally posted by EMDDIESEL:
Thanks for the info, how much does one of those turbo's cost (Estimate)?

Paid $1000 for HX-40 with 4" downpipe with 20% TDR membership discount from DD (Diesel Dynamics). They are also available from JRE, BD, Majestic, SportBike, Blue Chip Diesel, just to name a few.

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Kurt Voss
********* 1999 2500 24VCTD AUTO 4x4 QC LB Laramie SLT, Luverne stainless steel nerf bars, 3 piece bug deflector, mopar mud flaps, Line-X bedliner, Blue Chip Fuel Management System (Premium), Psychotty Air, DD3's,TTPM, DD 4" exhaust, HX40, DTT VB/TC(91%) , Mag-Hytec transmission pan... YEEEEEHAAAA!!

 

[BIG BOB]

I also talked to DD today. I was really worried that I would have to talk to the same guy that had to warranty my Psychotty. He should never be allowed to talk to a customer. Very rude. However Mark, who I talked to today was the greatest! They have been experiencing the same problem. I explained what I had to do in order to make the pipe work, with the slip joint and everything. They are going to give me a credit which I thought was very generous, Mark even asked if it was enough.

I have to admit that the experience I had on the phone with them today and Marks willingness to make sure I was satified was fantastic! Mark's customer service was amoung the best I've ever had.

My hat is off to you Mark. Thank you for your excellent service!

 

[daveg]

My BD down-pipe fit my HX40 perfectly and headed the right direction. The rest of the 4" system installed easily also. Good system.

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Dave Grindstaff 2001. 5 3500 quad cab duelly 4X4, SLT plus, ETH 6sp, 3:54ls, EZ, DD3s, propane, HX40/16, 4" pipe turbo to tail, Pyscotty air, Isspro's in pillar, Joe Donnellys modified Sachs

 

[work2muchplay2little]

Just wanted to conclude the saga for anyone interested. Even though I told Lawrence at DD that I didn't need the fixed HX-40 downpipe in a big hurry, he sent it overnight anyway, no extra charge. Another thing that speaks to the high quality of DD's service is I had ordered a TTPM, but got a regular boost module instead. They sent the TTPM, only charging me the difference, even though I hadn't yet sent the boost module back. Everything fits perfectly and I'm very happy with the performance of my truck #ad
I'm totally satisfied with my dealings with DD and will use them and recommend them to anyone again.

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Kurt Voss
********* 1999 2500 24VCTD AUTO 4x4 QC LB Laramie SLT, Luverne stainless steel nerf bars, 3 piece bug deflector, mopar mud flaps, Line-X bedliner, Blue Chip Fuel Management System (Premium), Psychotty Air, DD3's,TTPM, DD 4" exhaust, HX40, DTT VB/TC(91%) , Mag-Hytec transmission pan... YEEEEEHAAAA!!