I have a 2015 2500 I bought with 124k 68RFE that has a 4in turbo back exhaust and EGR intact tuning with a MM3 tuner. I had no history on this truck.
I started to get the turbo actuator position unknown code. It was off and on for a couple months, then it stayed permanently on and the exhaust brake quit working. I looked at 3 options.
Cheetah style turbo – cost around 2700-3000, I wouldn’t “have to” change tuning or manifold.
BD iron horn kit – around 1750 for a s366, still need and egr delete kit to block off manifold and egr, also will need tuning.
WC FAB 2nd gen swap- around 3000 for S463 and steed speed manifold, will need tuning and an EGR block off only.
I decided not to get a cheetah turbo because the actuator is still a failing point. I did not choose the iron horn kit because I wanted to have options down the road to run a larger turbo and it would be easier with the WCFab setup.
Here’s how I saved some money,
Order the turbo kit with-out the manifold. Use promo code ENTHUZS from Dirtymax Jack’s YouTube channel for free shipping.
Order the manifold from Garofalo, and you’ll get free shipping and free exhaust manifold studs (needed).
https://garofaloent.net/site/product...-turbo-flange/
Get your block off plate from Mayhem metal works for 15$ plus shipping
https://mayhemmetalworks.net/product...509e105d&_ss=r
Because I already had a MM3 tunner, Ray from DRD hooked up that department.
I sold my old turbo to Diesel Punk Core for around 375$, they paid shipping and I shipped it in the box my new turbo came in. https://dieselpunkcore.com
Tools:
Now, I’m in the Army and far away from my tools. I bought a craftsman tool set for like 125$ on sale and some extra metric wrenches. I ended up needing a 25mm wrench and a cutoff tool to get the coolant adaptor off the head. Also, a 15mm deep socket to torque the manifold studs. I had a torque wrench already.
Install - Early Dec 2019
First, I downloaded the tuning and made sure it worked correctly. I had the egr and cooler off in about an hour. The airbox, intercooler pipe, and loosened all the manifold bolts the next hour before going to bed. The next morning a buddy came to help me lift the manifold with the turbo attached out of the truck. I drained the coolant before that. I finished most of the install that day. I finished all the loose ends the following day. I worked mostly by myself.
Troubles:
I had to grind down the smaller side of the 25mm wrench to get the coolant pipe piece that gets blocked off in the head. It was really stuck on there.
The adapter that you have to cut your lower coolant tank hose leaked and I ended up buying a new hose and really tightening the clamps multiple times.
The other adaptor that goes into the engine by the oil filter almost touches the oil filter. You can barely put a piece of paper between them.
The intercooler piping doesn’t fit will. I’ve adjusted it many times and had the boot pop off the intercooler twice since install. I did buy a hump intercooler boot to connect the two pipes together. I have not installed yet.
My thoughts:
I love the kit and the tunes. Nothing else was upgraded at that time. I drove home for Christmas 1800 miles one way and back with only the boot popping off once. I highly recommend this kit and tunes.
Since then I have added head studs ARP 425, BD intake manifold, and EGT gauge. I just did the EGT today, so I don’t have any data yet. I will be towing this and next week, around 7k.
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