from gathering knowledge from some of the big shops around the country, most say the 3rd gen trucks run hot because when dodge boosted power, it came from programming. the turbos do not have much growing room in terms of air flow. you can increase fuel and get more boost but the added air gets warm. combine hot air with a small exhaust housing and temps get cookin pretty quick as well as backpressure. many of todays boxes load alot of fuel down low for great response but the turbo cannot catch up and cool the the intake charge enough...especially when the turbo is overspooling out of its efficiency range and warming up the pressurized air.
whats the solution? opinions will vary but my best response was a larger turbo if you want to keep you power levels up. your at a point where performance gets pricey and unluckily there's not simple or cheap solution. a smarty may be better programming but it will still heat your egts to unacceptable levels if your looking for strong performance with cool temps. water injection may also be an approach. usually good for a couple hundred degrees.
just be careful with egts combined with high backpressure...can be deadly to common rail valve seats.
good luck

 

I've been having the same noise lately with my stocker in 4th. Including the low boost. For about six months I clamped off the wastgate to get higher boost numbers and lower egts while towing. Thought this seemed to help I was getting nervous about killing the stock turbo due to constant bark from the clamped wastegate and tight T/C. When the noise started I took off the clamp and checked for play in the shaft and found nothing. Recently the noise has gone away. I believe the some of the niose was coming from a partially clogged CAT.

 

The single biggest reason that the temps are so high on 04.5 trucks is the retarded timing for emissions, retarded timing results in less smoke, less NoX emissions, decreased hp, decreased mpgs, and increased EGT's... .So a good box, like the smarty, puts the timing where it probably would have been if the EPA didn't tell cummins what the exhaust had to do for emissions, so you get a little more some, some increase NoX, more hp, more mpgs, and EGT's that are so low your jaw will drop.. I got 40 hp and about a 200* reduction with NO extra fuel.



J-man, sounds like you have an intermittent issue, you should read approx 32 psi of boost w/out any form of boost fooling, it will go up from there based on fueling loads. I can see about 34 psi with the wastegate disabled and my Smarty Jr on SW#1 (timing only), I also have not broken 1200* with the Jr software, even towing thru the mountains of Idaho.

 

ah64id----have you tried a wot 1/4 mile run yet?

 

Nope, but I have done WOT pulls on mountain roads towing 5K with a full bed... My dad has a 06 G56 with the JR and has seen 1250 on some mountain passes towing 7-8K at 75 in 6th... Hard towing will raise EGT's more than the 1/4.

 

I'm sending it back to edge so they can re-check everything. I hope they get it right this time!!!

 

i may not agreen with you on your egt analysis btwn towing vs 1/4, but either way, they are clearly both excellent ways to test fueling and efficiency of these great engines. thanks for the information .

 

lol im in same boat. my truck is now useless as i am awaiting fuel rail sender and FCA regulator but i see high egts like you. i have a 2004.5 and i can see 1500 with juice on stock. I do have other isspro gauges that i will hookup but i have not ruck or time yet to do so.Im hoping that it was my fca regulator that was causing too high egts. Plus im getting my ecm reflashed at dealer for a WHOLE PILE of updates. Maybe this will all correct this problem?

 

I got my j/a back and installed yesterday. they just sent me a new one this time. From a quick drive around last night, I still couldn't get over 33 #'s boost and temps still climbed pretty fast on level 5.. I need to put more time/miles into it and some pulling before I can say anything for sure.