Installing HX-40

[Vaman]

For those of you that have installed the HX-40, how did you work around the difference in the wastegate actuator orientation (90 degrees out from the stock HX-35)? This causes two problems. One, it's sitting directly where the cooling system (heater) line is. Two, the wastegate actuator and sensing line will be against the exhaust manifold. Did I get the wrong HX-40 or something and why would Holset orient it that way when it's obviously going to cause issues with the exhaust manifold? Truck is presently torn down in the driveway with no way to get the old system back on so any input would be greatly appreciated.

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98. 5 2500, 24v, QC, 4x4, 4. 10 LSD, short bed, Line-X liner, tow package, camper suspension, Westin nerfs, camper shell, TST PowerMax3, 275 RVs, ProComp A/T 305/70/R16s, EGT/Boost pillar gauges... Love my Cummins, no love for Dodge

[This message has been edited by Vaman (edited 03-25-2001). ]

[This message has been edited by Vaman (edited 03-25-2001). ]

 

[work2muchplay2little]

Vaman,
this may not help much but what I've come to understand (not having bought one yet) is that the turbine/housing assembly is rotated (clocked) specifically for our trucks by loosening the bolts, rotating, then retorquing. As for the wastegate actuator, the work-around is done by modifying (cut/weld) the rod 90 degrees from current location. Both of these are done prior to sale from BD and DD I believe. Good luck!

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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, unBOMBed... . yet

 

[Vaman]

Appreciate the reply. I had all the ports lined up (exhaust, intake, oil) by rotating both housings which wasn't too much trouble. The wastegate actuator is a different issue. I even took it apart to see if I could use the actuator from the new turbo with the mounting from the old one. The problem is the actual wastegate itself. I didn't see any way of changing that to work with the old mount because of the different approach angle of the actuator. I'm rerouting my heater hose right now which will get my turbo mounted but it still leaves the wastegate actuator too close to the exhaust manifold. Sure wish I had known this before I sawzalled my old exhaust... kinda screwed at this point.

 

[work2muchplay2little]

Vaman,

I found one other thing that might help you. This is a picture of an HX40 for our trucks from the Jannetty Racing website. It has a good view of the wastegate actuator.
http://www.jannettyracing.com/images/product_images/superturbo.jpg

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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, unBOMBed... . yet

 

[Vaman]

Yup... that's the way it's supposed to be for our trucks. It's apparently not how the stock HX-40 is shipped from Holset. Mine is installed with my heater line rerouted and the wastegate sensing line reversed to the other side of the actuator to keep it away from the manifold. Hasn't been a good day... after that I couldn't get my 4" exhaust in because the downpipe isn't bent quite enough. Want to know how your truck sounds with just a 4" downpipe? You don't want to... lol Bottom line is for all you guys looking for an HX-40, make sure the wastegate actuator is setup for our trucks.


[This message has been edited by Vaman (edited 03-25-2001). ]

 

[Diesel Guy]

Must be why DD and BD Engine Brake get the extra money to setup the HX-40's. Buying the cheapest isn't always the best.

 

[Vaman]

I don't think you'll find anyone in more agreement about the downpipe. Mine is just a few degrees off but it's enough that I can't get the midpipe in. You simply cannot appreciate what it's like to run with just a 4" downpipe and who knows how long I'm going to have to run like this. As far as the turbo, I've probably got a pretty unique install but it looks good... really didn't like that heater line where it was anyways. #ad

 

[csutton7]

Vaman-my downpipe was off too, but I was able to get everything hooked up--I was able to get the two straight pcs on but at the end of the 2nd pc I was hanging at least 3" below the bracket, so I just slowly(maybe about 5 minutes worth) pushed it up until I could get the clamp on and then I slowly brought it up via the clamp--took some time but it worked and is working fine--so your's is off by a whole bunch if you can't get the 1st straight pc on --wow--still have to reroute the water lines, I just bent that bracket out of the way for now but they're slightly rubbing the ATS exhaust)---and I flipped over the wastegate head(where the hose connects) to get everything in---chris

[This message has been edited by csutton7 (edited 03-26-2001). ]

 

[Briar Hopper]

The down pipe I have was purchased from Stan's Headers, and it's as slick as they come, I didn't have any trouble lining it up, they even supply a second piece of pipe with a hanger rod welded on it, near perfect line-up...
I had the same problem with my wastegate actuator... had to flip it 180 degrees, then bend the bracket for the heater line to get the line out of harm's way...
Even worse, I suffered through a few days with very little boost, before I tried disconnecting the wastegate rod, wiring the lever arm in a closed position, and plugging the hole where the elbow normally goes... Now I can hit 35 psi easy, my EGT's are down, and there's very little lag.
I'll have to try to shorten the actuator rod, it's evidently holding the wastegate open, in the length it's set at...
The 40 is now working so good, no regrets about installing it !

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Tom
Secretary of the Great Lakes Turbo Diesel Registry GLTDR B. A. D. Boys

 

[HEMI®Dart]

Vaman
Get a couple of feet of 4" flex exhaust pipe from a truck parts supply house. Its a high quality pipe. Fill in you void with this pipe. Its an easy fix. Get a couple of band clamps too.

 

[Vaman]

Again, thanks to all for the input. Hemi, I'll look at that flex pipe. As far as the HX-40 goes, I'm pretty happy. I'm getting well over 40 pounds of boost and the lag isn't much more than the HX-35. Once it kicks in, it's pretty impressive and my exhaust temps are definitely better. Big question now is... where do I get a plumbing kit to use both turbos? #ad

 

[BULLWAGON]

Tom... glad ya got it figured out!

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Black 1998 2500 4x4
GLTDR B. A. D. Boy

 

[Mopar-muscle]

Originally posted by Diesel Guy:
Must be why DD and BD Engine Brake get the extra money to setup the HX-40's. Buying the cheapest isn't always the best.

i'll have to disagree with this one , a friend just got one for alot less with a much better wastegate actuator setup . he still needs to get the exhausrt though , but will still come out ahead .

 

[Joseph Donnelly]

Wait until the exhaust epic is done, before saying BD or DD converted HX40s aren't worth it! #ad
Especially if you are paying labor to install something that doesn't quite fit. Clocking must be right on, and there isn't much room for the downpipe--it has to be carefully bent. #ad