Not sure what you meant by Cast Controller on the intake, but it looks like the guys have you going in the right direction.
I blocked the egr where it connects to the valve. 4 bolts come out and used the gaskets for templates. removed butterfly and unpluged the brown connector. That's it. Juice clears codes on start up. The hissing may be the e brake. There is a possibility that the e brake may be sticking a bit. I would run it all the time with the e brake as they are having issues with it sooting up and sticking. Take it and run it up in 4th gear, or 3rd if you need to and get the e brake to come on a few times to see if it is responding quickly. It should be instant to come on and off. If it is sticking this may loosen it up and make the problem go away. You shouldn't have any boost with the throttle off. Also make sure you have the egr completely blocked and nothing is getting by. Unhook the battery for about a half hour too while you check everything. This makes the computer go back to defaults and relearn.
Let us know if it goes away or not.

 

BTW, if the turbo vane is sticking, i.e. the e brake, the dealer will fix this with a CLEANING, which means they will drill a hole in it and flush it out with chemicals. Where the shrapnel from drilling the hole goes is beyond me. I have seen this turbo taken apart and I would never let them hack it up like that. Just a heads up in case that becomes an option for you.

 

When they do a cleaning do they need heat from the truck running to make the chemicals work properly? I'm thinking about getting a spare turbo and cleaning it up myself and I'm wondering if these chemicals will work with the turbo on my workbench.....

If you want to give the EB a workout then do as DieselLady suggested but do it in Tow/Haul and just keep giving it pedal and then letting off. That will blow some of that crap out of there.....

 

No, I think they just drill a hole in the turbo into the back side of the vane that slides in and out so they can flush out the excess soot. But now heres a thought, what if they are doing this while it is in the truck? I would assume they took it out and put it on the bench to do it, but what if they don't? At least a portion of that flushing liquid would have to go into the exhaust and get trapped in the dpf. Thats a scary thought too. Oh like I said, no hackers working on my truck. My imagination is just to active I guess.
Ya, tow haul mode, and work the crap out of the turbo. I think that's the best way to keep it clean.

 

I have a picture of the Turbo split apart for the new 6.7 dodge. If I do it right I may be able to attach it here. I hope!!

 

Sweet, let's try another one. I've been told they drill a hole right above where the oil supply screws in on this photo. Into the back side of where the vane slides back and forth. Eeeee Gads!

 

After Reconnecting the Gray plug on the unit on the exhaust side, and disconnecting the Brown plug on the intake side,
All of the problems are gone!
No more Hissing or boost rising while driving. I think the Hiss was the Slider (Waste gate for a lack of a better word) moving towards the Brake side, caused by the Brown plug connected, and the Gray plug disconnected.
The Exhaust brake is working fine, and I have not had a problem with it.
As for the Clean Out Plug, The dealer did this about a month ago, and he is now going to install a new Turbo under warranty (he knows what Mods. I have made) I told him I did not like the way they drilled the hole, as there is about 5 threads on one side of the hole, and about 2 threads on the other.
They drilled my Turbo between the Oil hole and the Water cooling hole. The Plug they screwed in is almost touching the Slider, it may actually touch the Slider.
The dealer said the new Turbo will have the clean out hole in it from the factory, maybe it will be a little better.

 

Well that's good news. That's the first I've heard about doing a clean out hole from the factor. Maybe they are wrong about that too. Hum.

 

Thats what he said. I'll let you know when I get the new Turbo.

 

Oh I believe you. It would just be really nice THIS TIME, if he was wrong and it didn't have the hole in it.
I have been fortunate to be able to hang out with some of the engineers at Borg Warner turbos occasionally, and just listening to them talk about some of the subtle changes they can make, and the results it gets is amazing. So hopefully if they are making a hole in it and plugging it, it will be at Holset, and not at Chrysler, if you know what I mean. Just me being picky!

 

Thanks for all you have given to this site!
It will be a couple of days before I see the new Turbo, But I'll let you know about the plug when I see it.
I'll be in there shop as they install it, or I wont let them touch it.

 

Thanks for all the info in this thread. That thread about EGR on the other site that is 50 some odd pages long is a lot less precise in info and seems to have more hearsay than this one.

 

Well, I was one of those involved in that thread from start to finish. This thread was started long after we came to our conclusions about the mod over there.

 

Has anyone actually taken their truck in for service to a dealer that is not "mod friendly" to have a repair after unplugging the EGR? Will this get you busted??

 

If all you did was unplug it then just plug it back in. I don't see where you would have a problem. If your CEL is still on then ask them to check out why...