BD Howler VGT Turbo Kit for 2004.5 - Anyone with Experience?

[eastmentCTD600]

2004.5, 4x4, ATS built 48RE, 194kmiles, BBI Stage 0.5 w/8-hole nozzles, Original owner.

I have exhaust manifold leaks on Cyls 1 & 6 and decided to replace it. While doing so I also removed and inspected/disassembled my stock Holset HE351CW turbo. Turns out the exhaust manifold was not cracked but my turbine housing was. Mostly used for towing/hauling and is not a daily driver.

Turbine exhaust housing was found to have some significant cracks (see attached photos) and the cartidge has some excessive radial play. Axial play seems fine.

Therefore, I'm considering upgrading to the BD Howler VGT kit with the stock HE351VE and controller. I run a Smarty Touch and BBI Stage 0.5 injectors. EGT is high when towing 10 - 12k across Colorado. Wanting to upgrade turbo for better spool, lower EGT, and increase in power potential. Either twins or possibly this BD kit appear to have these benefits and would check all the boxes. Plus the integrated exhaust brake would be nice. Has anyone installed this kit and put some miles on it? Impression, issues, pros/cons, exhaust braker performance? Any advice would be appreciated!

 

[promisedland]

Can't answer your question but it should work well. I'm fascinated with this turbo.

 

[eastmentCTD600]

BD has some reviews on their website which are mostly positive and promising; however, some indicate issues with proper operation of the VGT nozzle ring under cruise control conditions. From what I gathered, and let me be clear this is my best guess, the system must have user throttle input (changing the physical throttle position) which then is used to calculate VGT nozzle position. Under cruise control, for some 3rd generation models, the throttle position, or input to the ECM, is completely computer controlled, and the physical pedal position is unchanging. Thus the APPS position, which I assume BD is monitoring, is not changing. Therefore the BD electronic controls only see APPS position of zero while cruising. This might lead to a condition of ‘APPS position = 0%’ to act on for calculating the target VGT nozzle position. This means the nozzle is effectively stuck in one position during cruise which is not desirable. To be clear, this is my best guess based on “the internet” so take that for what it’s worth…

In my case, having an 04.5 with vacuum-controlled Throttle Position Sensor (TPS) in Cruise Control (CC) mode I would think the perceived issue described above would not apply to my specific truck. For mine the cruise control directly/mechanically controls the throttle position and the associated sensor. I can feel it acting on the pedal under cruise mode. I can only assume other 04.5 trucks have the same vacuum pump, diaphragm/cable, and vacuum reservoir system to manipulate mechanical throttle position sensor just like a user pushing the pedal. If I recall correctly, the 05+ went to an Accelerator Pedal Position Sensor (APPS) sensor at the pedal and the cruise control function for these trucks does not physically act on the pedal in any way. This *could* potentially mean that if BD’s electronics rely on APPS position and do not access or use the electronic cruise control parameter from the CAN bus then the VGT would not have input to adjust the VGT nozzle under CC. For me, proper operation under all conditions is a must have so I’m waiting to see what they say.

I put a question into BD tech support for some clarification about the 04.5 on 01/16/25 and I will post an update when I hear back.

 

[Ozymandias]

Good information here.

 

[CharlesinGA]

I researched the BD Howler kit as a possible exhaust brake method. Other than price, the one issue I found, was in a review of the kit. The fellow had installed the kit and then found that if he didn't featherfoot the accelerator, the computer would set codes. Basically when he talked to BD after that they admitted that you needed to install higher flow injectors to match the turbos airflow capabilities. Apparently you don't have problems until you give it a little too much throttle and the injectors cannot keep up. I might have looked further at the kit if they had a turbo more closely matched to the engine/original turbo.

I was not looking for more power, only the exhaust brake, so I finally installed the PacBrake kit.

Charles

 

[eastmentCTD600]

I heard back from BD on the cruise control question for my 04.5. It should work fine with cruise. It also should work with other years. The manual has a cruise control test protocol for 2003-2004 and 2005-2007. The protocol specifically excluded 2004.5, because I suspect, the 04.5 was the only one with a vacuum operated throttle pedal, thus no need to test anything. The cruise control directly controls throttle position, just like your foot thus it should be fine and it will disengage when you hit cancel or tap brakes.

My thanks to BD for answering my questions.

though now I’ve done purchased a DPS Turbonator with electronic exhaust brake which should be installed around 01/30/2025. Turbo is a S363/68. Stay tuned for an install and initial performance review… possibly in a new thread…

 

[promisedland]

https://www.dieselpowersource.com/choose-your-own-turbonator-vgt-vnt-variable-geometry-turbo-cummins
This one?

 

[eastmentCTD600]

https://www.dieselpowersource.com/choose-your-own-turbonator-vgt-vnt-variable-geometry-turbo-cummins
This one?

Yes, that one. Electronic control/exhaust brake with the S363/68 turbo. I also purchased a turbo blanket.