NJTman

Looking forwards to "incredible"...

NJTman

Exh housing in hand....

Now all I need to figure out is what I'm doing with the turbo.

NJTman

Placed an order for all my parts from Gillett Diesel.

Steve answered all my questions, and set my mind at ease.

Would recommend them ....

NJTman

See below

mknittle

This is what I eventually want to do to mine.

NJTman

You get the benefit of me doing it first


You bastage

Lol

thrashingcows

My HX35 took me weeks to get the hot and cold sides to come apart....heat cycling, then beat on it with hammer, even tried pickle forks, and the nuts and bolt to try and separate them. Eventually it came apart, then the cheap off shore rebuild kit killed it first time out around the block....

ALWAYS pay top dollar for your turbo rebuild kits!

NJTman

Hopefully, Gillett Diesel comes through with quality parts, otherwise I blew $100 on a rebuild kit.

NJTman

So, it took a couple hours.

At first I figured the PB Blaster would do the job, and I'd be golden.

Nope. Didn't even migrate a millimeter through the rust joint. Had that thing soaking for a couple hours, and then wiped all the PB off. scraped with a pick in the joint between turbo and housing, and it was still dry beneath.

So what I do ? What I always try to do. Something different, something radical. I cut a relief in the housing, and it popped right off. The PB Blaster didn't penetrate at all. Bone dry below...

Was very careful not to damage the turbines in the exh housing.

NJTman

So, the turbine housing that I had was a 18.5cm unit. I thought it was a 21, but I was incorrect. No matter, as the difference is noticeable, with the improved "peppy-ness" of the truck's throttle response. The EXH temp gases are much hotter as well.

Had to grind the remaining bolt off the housing that wouldn't come out. Couldn't access it, so I cut a space to get my grinder in. Mounting plate got a bit buzzed, but it's fine otherwise.

The new housing needed a little tweaking. It was cast a bit ugly, so I used the gasket and did my best to "port match" it up a bit. The exh manifold was fine, but it would have been hitting the face of one side of the housing if I just bolted it on. I had to be very careful, though as the thickness of the housing is minimal where the casting was off. It's where the bolt flange insets are, and I was sure not to disturb the thickness where it would cause an issue by being too thin..

NJTman

I made sure that no junk went into that turbo drain tube, as that's the last thing I needed to happen.

Bolted the exh housing up first so I could properly clock the turbo in the housing. Took a bit of being a contortionist to get that bottom bolt in, but that's nothing new with these trucks...

Truck definitely runs better. Runs HOTTER. The turbo can easily be removed in a few minutes now that all the bolts have been neverseized, and the next fun will be to upgrade the turbo itself to get a bit more wind in the engine. I get to now experience each modification for a while to get a good idea of what works and what doesn't.

oliver foster

Nice work as usual T-man!
The casting did look a little ugly. Good call on the light porting to match the gasket better.
I am glad you like it as going back to the old 18.5 housing doesn't look like an option.

mknittle

I somehow missed the porting part.

MrFusion

I ended up letting my turbo sit in the parts washer for a couple weeks. Every couple days I would take it out and give it a few whacks with a 2lb sledge. Eventually it popped right off. One advantage to having a non road worthy truck is that there isn't much of a rush for anything.

NJTman

So, I've been driving the truck about for the last two weeks with the new exh housing on there. Things I've noticed.

Almost zero smoke on acceleration.
much quicker spooling and better acceleration
better fuel mileage ???? Is that possible ?


and the new toys came in from Gilette. Real cummins seal kit, housing, 60mm wheel and fuel pin. Thanks for the tips, guys.

Hopefully get it done sometime over the next week or so, although I cannot test it because of the steering gear being out.