Single Turbo Towing Upgrade 04.5 HO

[trailexplorer]

Hi TDR. So I have been doing my do diligence in researching a single turbo upgrade for my 04. 5/ 3. 73/ 6 spd/ quad cab/ dually. I tow at max GVWR (perhaps a shade over here or there).



My issue is I have a cracked stock manifold (I have read up on problems) and a small crack in the turbo housing (read up on problems).



I am definitely purchasing a 3 piece manifold. Suggestions? ATS has been at the top of my list since I bought my Cummins and I have finally waited out the warranty. I AM MY OWN WARRANTY.



Looking for personal experience with max loads. Here are my Specs:



Full AFE intake w/ silencer ring and baffles lost, juice hot w/ attitude, free flowing 4" with muffler, haisley dual disk clutch with pyro post turbo. I have always kept the EGT's no higher than 1000 with the exception of very short durations. My truck has had little time moving while not strapped to the my 40' fifth wheel.



I understand that I may have to deal with a small amount of lag over stock with an upgrade but I am looking for something to push a bit more air without a lot of lag. My truck runs very good as is but would like to take advantage of the cooling I know can happen with a 12, 13, 14????



Appreciate any info TDR. FYI, twins are out of the budget.



Stock turbo will be available w/ crack.



P. S. any info on sealing the marker lights on the cab. Darn things started leaking with the rain this week? The seals look okay?



Thanks all.

 

[wcjp]

Can't help with Turbo. Have you considered LED lights for the camper? Then fully seal the light

 

[MChrist]

There was a write up in the past few days about a S300 (I think). The poster really liked it, but said it had a little more lag than stock, but quickly adapted to it and prefers it over stock now. Search and you should be able to find it.
Mark

 

[MChrist]

"S-300 custom turbocharger review" from Gonzo 1066
Mark

 

[JJPage]

Super B from BD(57/65/14) would be an excellent choice, it will flow more air than your stock 60/60/9. BD can also fill your manifold needs, you could use their 2nd gen, center dump manifold with minor modification to downpipe and intake tube.



Another option could be a 62/65/13 from HTT, they are a direct bolt in with the stock exhaust manifold, not sure about an ATS...



I actually towed my 5vr toybox very well with a SPS 62/71/14 from Industrial Injection, however you stated pretty much full time towing, the 65mm turbine would suit your situation better.



If you do a search on post's by JStieger, he had some really good information on single turbo upgrades, Specifically the SPS62.



EDIT: I tried finding the thread for you, could not find it... Maybe wrong spelling of name, or he changed user name?



FOUND IT: https://www.turbodieselregister.com...7/146574-prototype-super-phat-shaft-62-a.html

 

[Gonzo 1066]

I have been VERY happy with the Schwitzer S-300 that I got from PDR. I had a ATS manifold and the addition of the S-300 made my 04. 5 3:73 6speed dually a real tow monster. I would consider this a "Best Buy" as far as my truck performance purchases.

 

[trailexplorer]

Thanks for the feedback all. Appreciate it. Would a 12 reduce the lag significantly vs a 14? I plan no more fuel / performance upgrades other than what I currently am running. I really like the stock rev up in all gears and am concerned about lag between gears.

 

[JJPage]

You should pm TWest(T&C Diesel), I believe he is running a 12cm housing.

 

[jelag]

I have installed 3 of the ATS (their stock design) that is the 2 piece manifold... we don't have any of our trucks with the HP turned up... . in each case we've cracked the stock manifold or snapped off the 2 rear bolts... BTW the broken parts were easy to get out...

We are pleased with the ATS design and how it works... we tow up to a 20K lb trailer... I'm sure if we'd have turned up the HP we'd have other issues but we're OK with the stock engine and several different drivers...

I wanted to try the BD design but I couldn't find anyone in the US with one on the shelf and BD only takes product across the border once a week... which at the time I'd missed by hours..... so we went with the ATS design on the first one... . liked it and bought 2 more... .

I've also sold 2 other ones to family... .

I hope this part helps... .

 

[trailexplorer]

Super B from BD(57/65/14) would be an excellent choice, it will flow more air than your stock 60/60/9. BD can also fill your manifold needs, you could use their 2nd gen, center dump manifold with minor modification to downpipe and intake tube.



Another option could be a 62/65/13 from HTT, they are a direct bolt in with the stock exhaust manifold, not sure about an ATS...

Anyone have current first hand experience with the S

I actually towed my 5vr toybox very well with a SPS 62/71/14 from Industrial Injection, however you stated pretty much full time towing, the 65mm turbine would suit your situation better.



If you do a search on post's by JStieger, he had some really good information on single turbo upgrades, Specifically the SPS62.



EDIT: I tried finding the thread for you, could not find it... Maybe wrong spelling of name, or he changed user name?



FOUND IT: https://www.turbodieselregister.com...7/146574-prototype-super-phat-shaft-62-a.html

Anyone have current experience or updates with the Super Phat Shaft 62. I would like to retain close to stock spool but push more air.



Will this turbo bolt to the factory jacobs brake?



Thanks JJPage for the post link.

 

[MMeier]

TE, I have that one on my '03 , love it, runs a bit hotter till you get above 15-20 PSI , then it 's fine, compared to the stocker. Used to hotshot with a 40' GN that would gross 36k ' on occasion' ! Now I just tow my itty bitty 20' enclosed race trailer, just got in from PHX and it runs extremely well in our desert wintry weather . Has been on the truck for almost 70k miles now, along with the 3 piece manifold. Oops, almost forgot, Jacobs brake bolts right on.

 

[AH64ID]

I agree on the S-300.

62/65/12 or 62/68/12 would be my two votes. But it also depends on what tune you tow on.

Also to keep your EGT's under 1000 and towing at Max GCWR you must have a post-turbo probe.

If you tow at or near stock hp then you may also consider a HE351VE with a Fleece controller, cheaper and has an exhaust brake included.

 

[JJPage]

I agree on the S-300.



62/65/12 or 62/68/12 would be my two votes. But it also depends on what tune you tow on.



Also to keep your EGT's under 1000 and towing at Max GCWR you must have a post-turbo probe.



If you tow at or near stock hp then you may also consider a HE351VE with a Fleece controller, cheaper and has an exhaust brake included.

Many improvements have been made on the S300 frame in the last few years, with many more wheel sizes/housings available, (62/68/12) looks interesting. I would still prefer a 13/14cm housing.



How does the post turbo probe help with controlling egt's? I think I understand, by monitoring post turbo, you can make adjustments?(back off the pedal).

 

[MMeier]

Many here will agree the probe should be PRE turbo, not post. But if you must ... there is "usually" a 300-350* difference in readings between the two positions... with PRE being hotter.

 

[WOT]

I love my HTT 62/65/13SS. Not much difference on spool that I can tell from stock and cools well.

 

[AH64ID]

Many improvements have been made on the S300 frame in the last few years, with many more wheel sizes/housings available, (62/68/12) looks interesting. I would still prefer a 13/14cm housing.

I guess it really depends on what rpms your turn most of the time. If you tow at higher rpms then get a 14, if you want quicker spool and tow in the lower rpm band a lot get a 12. The 14 will spool slower, but run a little cooler on top and the 12 will spool quicker and a little warmer up top.

Super B from BD(57/65/14) would be an excellent choice, it will flow more air than your stock 60/60/9.

The Super B (850 CFM) is not much of an upgrade to the HE351 (809 CFM) , its a little to the 03-04 HE341 (650 CFM) , but not worth the cash on an 04. 5. BD Knows this and said they are working on a turbo geared towards the common rail between the Super B and Super B Special. On the same note an Aurora 2K is rated at 850, but nobody says to use it on a 3rd gen.

How does the post turbo probe help with controlling egt's? I think I understand, by monitoring post turbo, you can make adjustments?(back off the pedal).

Many here will agree the probe should be PRE turbo, not post. But if you must ... there is "usually" a 300-350* difference in readings between the two positions... with PRE being hotter.

Exactly, post turbo can have a 100-400* disparity from pre-turbo, and is always colder. Pre-turbo lets you accurately monitor the max EGT's the enigne is making. The only time post is better is when monitoring for shutdown as you can see when the residual heat from the turbine is gone.

 

[trailexplorer]

I love my HTT 62/65/13SS. Not much difference on spool that I can tell from stock and cools well.

That was the turbo I had fallen for; however, Industrial Injection and Big Power Diesel (via HTT?) stated that the stainless has a greater likelihood of seal failures if there is a exhaust brake (I have a stock Jacobs) immediately adjacent to the turbo do to the immediate back pressure created. The greater flow efficiency of the SS housing apparently works against itself with the brake engaged. They recommend no brake or an inline if your must have one. The cast housings have more restriction and thus the brake has less, albeit some, detrimental effect on the turbo life with the Jacob engaged.

I tow @ 25000 lbs 95% of time and use the brake very regularly to control my speed. Thoughts?

I am back to the 62/65/12 vs 62/65/14 vs the 62 phatshat dilemma. I would prefer not to have to add more fuel to spool a larger turbine if I don't have too. I only have a hot juice that I am rather happy with.

 

[trailexplorer]

So further thought has me asking the following question; If I delay the engaging of the jacob brake until the boost has reduced to single digits with the HTT 62/65/13 SS, will that reduce the back pressure issues leading to seal failure? FYI, I am planning on the one piece stainless manifold.

 

[WOT]

That's the first I have heard about the ebrake and stainless turbo combo but I didn't consider the ebrake when I purchased mine. Another option might be the aurora 4K, twins with stock turbo. I bet you can likely pick up a stocker from someone one the forum that has upgraded.

 

[AH64ID]

That was the turbo I had fallen for; however, Industrial Injection and Big Power Diesel (via HTT?) stated that the stainless has a greater likelihood of seal failures if there is a exhaust brake (I have a stock Jacobs) immediately adjacent to the turbo do to the immediate back pressure created. The greater flow efficiency of the SS housing apparently works against itself with the brake engaged. They recommend no brake or an inline if your must have one. The cast housings have more restriction and thus the brake has less, albeit some, detrimental effect on the turbo life with the Jacob engaged.

I tow @ 25000 lbs 95% of time and use the brake very regularly to control my speed. Thoughts?

I am back to the 62/65/12 vs 62/65/14 vs the 62 phatshat dilemma. I would prefer not to have to add more fuel to spool a larger turbine if I don't have too. I only have a hot juice that I am rather happy with.

To be perfectly honest the more I research a SS housing the less I want one, seems to be a lot more issues with them than normal cast housings. Just go cast, you'll flow fine and will probably get a longer life from it.