DPS versus BD Manifold Replacement

[Silver Tex]

I am getting ready to install a new PAC Brake and thought I would upgrade the exhaust manifold. Do any of you have opinions (strong or otherwise) regarding DPS or BD, 2 piece manifolds? Perhaps there are others that should be considered. I don’t have any turbo work/replacement planned, just leave the stock in place.

Thanks all,
Scott.

 

[Chase Chapin]

Scott,
I have been happy with my BD manifold. It even has a different tone than the old stock manifold, plus they are a quality product for a more reasonable price IMO. A word of advice on the Pac Brake, make sure you install a new v-band clamp on the elbow. I seals better than the old one! Hope this helps! (you'll love the exhaust brake btw)

 

[Ozymandias]

Same here, BD, I even think the Turbo spools a little faster then with the OEM.

 

[DavidC]

The BD looks nice. I kind of disagree that the gaskets are sold seperately for a whopping 80 bucks tho. Maybe just me.

 

[Ozymandias]

Yeah, that 16$ MAHLE seal kit could really be included.

 

[Silver Tex]

Yeah, that 16$ MAHLE seal kit could really be included.

 

[Silver Tex]

Haha! I should really write something before hitting enter.
Sounds like BD. Anyone experience the installation challenges with the #5 cylinder, lower bolt and its clearances? Best place to buy? I have it on my list at Thoroughbred Diesel. I have really gained an appreciation for Wade’s video’s and commentary. I’ll likely buy my PAC brake there as well as it is currently priced very nicely at $1149.00 including air.
Chase, thanks for the heads up on v-band clamp.
I really appreciate everyone’s feedback and endorsement.
Thanks,
Scott.

 

[BigPapa]

My ATS has served me well on my old dinosaur. I’d also suggest checking Power Driven Diesel.

 

[Chase Chapin]

Haha! I should really write something before hitting enter.
Sounds like BD. Anyone experience the installation challenges with the #5 cylinder, lower bolt and its clearances? Best place to buy? I have it on my list at Thoroughbred Diesel. I have really gained an appreciation for Wade’s video’s and commentary. I’ll likely buy my PAC brake there as well as it is currently priced very nicely at $1149.00 including air.
Chase, thanks for the heads up on v-band clamp.
I really appreciate everyone’s feedback and endorsement.
Thanks,
Scott.

Scott, if you haven't already taken the plunge, definitely go with Geno's on the manifold. They include the 89-07 gaskets for no additional cost! and no problem on the clamp advice, I figured it out too late and had to go back and install the new one, no biggie, just extra work ya know? I don't think you would have much trouble with the #5 cylinder bolts since you'll have the turbo and exhaust elbow out already to install the Pac.

 

[Silver Tex]

Scott, if you haven't already taken the plunge, definitely go with Geno's on the manifold. They include the 89-07 gaskets for no additional cost! and no problem on the clamp advice, I figured it out too late and had to go back and install the new one, no biggie, just extra work ya know? I don't think you would have much trouble with the #5 cylinder bolts since you'll have the turbo and exhaust elbow out already to install the Pac.

Thanks again Chase. I have an account with Gene’s so I will go that route. Again, I appreciate the heads up on who supplies most with what when it comes to the manifold. Maybe it is just me, but I thoroughly enjoy doing the things that make the truck just a little bit better and more functional.

Scott.

 

[Silver Tex]

So one other thought. For you guys who have done this, did you install a new set of manifold bolts or just reuse the existing fastener’s - presuming they are in good condition. The torque on them isn’t much - 35 lbs I believe. Just not sure if the heat cycle life has an affect. 120K miles and I am the original owner. No current leaks or evidence of cracking.
Thanks!
Scott.

 

[Ozymandias]

I went with the OEM bolts but just because of lack of availability that day for new ones. Get a set from Dorman,# 03417B, they fit for the aftermarket manifolds as the heat shield anyway don't fit anymore over it.
Cyl#5 bolt is delivered from BD in the kit, it's an Allen head metric bolt. Works as desired.

At install, be very careful with lining up turbo and elbow as this connection is NOT self centering. If it isn't perfectly aligned it will leak. I've redone this 3 times till it was leak free.

 

[BigPapa]

My ATS came with Allen head bolts. I torqued them on install and re-torqued them after three or four heat cycles. Haven’t had any issues in the past 250K miles.

 

[Silver Tex]

I went with the OEM bolts but just because of lack of availability that day for new ones. Get a set from Dorman,# 03417B, they fit for the aftermarket manifolds as the heat shield anyway don't fit anymore over it.
Cyl#5 bolt is delivered from BD in the kit, it's an Allen head metric bolt. Works as desired.

At install, be very careful with lining up turbo and elbow as this connection is NOT self centering. If it isn't perfectly aligned it will leak. I've redone this 3 times till it was leak free.

Hey Oz’s,
Are you referring to the elbow out the exhaust side of the turbo? If so and as Chase mentioned above, I’ll put in a new v-band clamp when I install the PAC Brake. If not, can you please clarify which elbow?

Thanks,
Scott.

 

[Ozymandias]

Yes, the connection between turbo housing and elbow is a little bit delicate.
I re-used the clamp as it is horrible expensive and a dealer only part.

Like mentioned, re torque the bolts after one or two heat cycles is crucial.

 

[Silver Tex]

Yes, the connection between turbo housing and elbow is a little bit delicate.
I re-used the clamp as it is horrible expensive and a dealer only part.

Like mentioned, re torque the bolts after one or two heat cycles is crucial.

Thanks Oz,
I did buy new clamps for each side of the cast elbow, which is now being replaced by the PAC Brake, on the exhaust output on the turbo. Yes and understood on re torque after the heat cycles. I went with the BD, 2 Piece Pulse manifold from Geno’s as well as the v-clamps from Geno’s - free gaskets (Chase).

I’m still deciding on the type of new studs. The Dorman set you suggested has a price point appeal, but BD has a set for about 3X ($75) that also has my attention as it has 4 studs/nuts/washers, with the balance being bolts. I’m not actually sure why I am contemplating this beyond perhaps ease of installation might be gained with the studs????

I ordered the PAC Brake from Thoroughbred Diesel. I will be contacting them this morning as the PAC Brake website suggests they offer one of two specific clutch interfaces and I am not certain the kit that I ordered has that interface. If anyone monitoring this thread that is running a 6 speed PAC Brake and has input, I’d appreciate it. In any case, I’ll find out when I talk to T.B. Diesel this morning. Regardless, looking forward to these upgrades and even the therapeutic aspect of installation.

Thanks!
Scott.

 

[AH64ID]

Scott, your 06 should not need any clutch interface to run an EB. The ECM is already setup to control the EB.

 

[Silver Tex]

Scott, your 06 should not need any clutch interface to run an EB. The ECM is already setup to control the EB.

Cool!
Thanks John.
Scott.

 

[CVR222NV]

I’m still deciding on the type of new studs. The Dorman set you suggested has a price point appeal, but BD has a set for about 3X ($75) that also has my attention as it has 4 studs/nuts/washers, with the balance being bolts. I’m not actually sure why I am contemplating this beyond perhaps ease of installation might be gained with the studs????

I had a stud kit but the bolts would not stay tight. Kept backing off because the studs were too short. Tried to find longer studs. Nothing. I even called ARP thinking they do studs for all types of applications and their technical guy stated they decided to stay away from studs for diesel exhaust manifolds. At the recommendation of PDI I went back to the OEM set up (bolts and spacers) with one modification. The flange on the PDI manifold I purchased has heavier flanges (+1/8") over the stock manifold so I purchased 70mm 10.9 bolts (stock length is 65mm). Furthermore, after numerous discussions with many of the exhaust manifold retailers I torqued the bolts to 40 ft. lbs. I have had two towing runs on my current set up and have checked the bolts and everything is holding up fine. Since you purchased the BD manifold you should probably bite the bullet and go with their studs if that's the way you want to go.

https://pdidiesel.com/collections/exhaust-manifolds/products/5-9-common-rail-exhaust-manifold

 

[Silver Tex]

I had a stud kit but the bolts would not stay tight. Kept backing off because the studs were too short. Tried to find longer studs. Nothing. I even called ARP thinking they do studs for all types of applications and their technical guy stated they decided to stay away from studs for diesel exhaust manifolds. At the recommendation of PDI I went back to the OEM set up (bolts and spacers) with one modification. The flange on the PDI manifold I purchased has heavier flanges (+1/8") over the stock manifold so I purchased 70mm 10.9 bolts (stock length is 65mm). Furthermore, after numerous discussions with many of the exhaust manifold retailers I torqued the bolts to 40 ft. lbs. I have had two towing runs on my current set up and have checked the bolts and everything is holding up fine. Since you purchased the BD manifold you should probably bite the bullet and go with their studs if that's the way you want to go.

https://pdidiesel.com/collections/exhaust-manifolds/products/5-9-common-rail-exhaust-manifold

Yep, I did end up going with that stud kit. I appreciate the insight. Some of the information I have read suggests, with anti-seize, to torque to 39 ft.lbs instead of the factory 35 ft.lbs.
Thank you,
Scott.