Turbo upgrade advise (High EGT,s)

[Brad R Foster]

Hello all im a little new to the game. I have a 1993 F350 4x4 4 door ZF 5 speed 3.73 gears on 35 inch tires
I have installed a 1992 Gen 1 5.9 out of a wrecked truck. engine mods are a dps fummins exhaust manifold for the 5.9 in a ford conversion a HE351cw with the servo removed and plugged full for inch exhaust with a straight through muffler (im happy with the sound - no droning when towing) I installed 5x12 vco 145 angle injectors from The Hungry Diesel I had the injection pump rebuilt at Oregon Fuel Injection with there off road tune a BD fuel Pin and a 3500 rpm spring I stalled a upgraded 3 inch intake and IC tubing and a 1999 power stroke inter cooler.
before rebuilding the injection pump i played with all the settings i was getting over 40 psi boost and smoked like crazy but it was fun but i built it for towing so its set at Oregon fuel injection off road settings, with 0 deg timing im making about 37 pounds boost and is very drivable and ok power towing
my toy hauler weighs about 13000 loaded on the freeway it tows great but on the long steep hills im trying to keep the RPMs up but as i lug down my temps go up and i shift down i end up at 35 mph in 3rd gear and i try to keep the egts no more then 1200 deg, I ran the temp up once to 1450 egts and got right out of it.
Is this normal or Am I expecting to much out of this combination
i talked to The Hungry Diesel and he recommended up grading the turbo to a Borg Warner S362SXE
( https://www.thehungrydiesel.com/product.sc?productId=2117&categoryId=350 )
to get rid of the heat and faster spooling

thanks for any advise or experiences
Brad
sorry for the long post

 

[AnonEd]

Sorry I can't be much help...no experience w/either of your turbos on my 5.9 VE...but I'm wondering if this is just lack of cooling? IIRC your intercooler was designed for a 235-hp/500 lb-ft engine and yours is likely well beyond that. W/my aftermarket intercooler, if wastegate is adjusted to 25 max water temp goes up before EGT, at 20 psi it's the reverse. I might verify with THD if you have enough cooling for pulling 20k gross up long grades before swapping a turbo.

 

[Brad R Foster]

I never thought of that I'll ask around about a better intercooler
Just seems like this thing should have more ability than what I'm getting

 

[RWherley]

The turbo is your issue, I had a HE351 on my truck for a while, they spool nice but the exhaust side is to small, 9cm if i remember right, You need some thing more open on the exhaust side, im running a Holset HX Super 40 on my truck which is a 60mm inducer on the intake and mine has a 14cm exhaust snail running 5x14 injectors plus my other mods i see a top EGT around 1300

 

[cerberusiam]

That is too much weight and too tall a tire for any kind of decent towing on a grade. As you said it works good on the flat but not so good on grades. More air is going to help, since you have a manual it will be easier to spool a bigger single.

0 degrees of timing is going to hurt power and drive observable EGT's a LOT higher, you need to put some advance into the pump then test again. Remember you can run 1200 degrees pretty much all day long with 8-10 degrees of timing so a couple minute spikes to 1400 or so is not going to hurt the engine, all things being equal. That might be enough to roll those grades at a decent speed, just have to test.

You need to drop tire size to no more than 33" tires, or, change axle ratios to 4.10's if you want any hope, aside from compounds, to keep things in check with that weight. Way too much engine load with 3.73's and 35" tires.

At 37 psi that H351 is pretty much maxxed out and with the late timing you are stacking the exhaust flow pretty hard, you can lose some flow by raise the combustion dwell a bit.

 

[RWherley]

Cerberusiam brings up some good thoughts, i just looked at your exhaust manifold, is that the only set up that will fit in your truck? putting this on my truck also helped a lot.
https://steedspeed.com/shop/cummins-2nd-gen/t3-12v-straight-turbo-flange/