Engine/Transmission (1998.5 - 2002) HY swapped for HX-35 today

[twiisted71]

If any of you is considering this swap but are wondering about the difficulty. Just go ahead and dive in. This has to have been the easiest bolt-on I've ever done for a major component. From start to finish (moving the truck onto a concrete work space till my tools were back in the box) took about 45 minutes! That was with me never having done one before. Knowing what size all the fasteners are, I figure you could probably do it around 30 minutes.



4) 15mm bolts manifold to turbo flange

2) 10mm bolts oil drain tube flange to turbo

2) 13mm bolts exhaust flange to turbo outlet elbow (lots of extensions)

3) 3/8" bolts? that hold the air box to the fender (didn't have to remove but seemed like it would give lots more room to move things)

2) 7/16" hose clamps from turbo to intercooler (deep well sockets)

2) flat blade screw driver hose clamps on air tube from filter to turbo inlet

1) 15/16" oil line nut that feeds turbo (line that comes from top of oil filter)

1) 3/4" adaptor fitting from oil line to turbo oil inlet



RESULTS---

EZ on middle setting

lost a little responsiveness with the HX. boost seemed to max out around 28 psi. EGTs maxed out around 1050 pre-turbo at around 105 mph. that is what I was really after. before 1200-1250 was no problem with the HY with no buckle. with the buckle it would do about 1150 and boost would have to be around 32 but it wasn't smooth, just a little accelerator change would have a huge impact on the boost. the HX seems very happy putting out 28.

I haven't towed yet so no info on that yet. Oh yeah you can hear the turbo more now too.

 

[SnoKing]

OK, I am planning to do the HY to PDR35 swap today, and it appears that I will have to get two new grade 5 or 8 bolts for the top two flange to manifold bolts, as my HY has studs screwed into it there. The bottom two are studs in the manifold so that is OK. SNOKING

 

[SnoKing]

Anyone know what size these bolts should be? SNOKING

 

[SnoKing]

Got it done with two 7/16 grade eight bolts from NAPA. Bought them 2" long to get the unthreaded part about 3/4 long to aid in alignment. They fit thru the manifold and turbo fine, had to explan the gasket holes a hair. Shorten them with a cut off blade in my Dremel tool. If you ever have to remove a case harden padlock, these little blades will do that also!!! Just make sure you have 2 or 3 available.



SNOKING

 

[SnoKing]

BTW, got 75 miles on the new turbo this afternoon. Drive-a-bility seems about the same as the old HY35, but I have not get on it very hard yet. Will be towing the 5er at Thanksgivens, that is the test I am waiting for. However with the cool weather it may not be that good of a test.



It took me several hours to do the swap, but I have the Banks Exhaust Brake, new heat shield to mount (Larry-B's) had to run to town for the bolts, then cut them and clean up the threads. Used anti-sez on all the bolts.



SNOKING