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Stu
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21,192 Posts
Discussion Starter #1,601 (Edited)
First mod will be install the ball bearing 80mm GT45 turbo. What I'm looking to do here is to get the boost up quicker and to utilize the upper rpm power band of the stage 4 turbo cam. If it works, wont have to change out the stage 4 turbo cam.
Then get another straight threw 4" diesel muffler. The 36" Magnaflow muffler is a 4" in/out but, reduces down to a 3 1/2" inside. With a full length, quiet exhaust system. It needs to be 4" all the way through to try and minimize back pressure for optimize turbo performance.
 

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Stu
Joined
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21,192 Posts
Discussion Starter #1,602
Everything bolted right up except for the down pipe. The GT45 has a 1.15 a/r exhaust turbine housing. The 88mm turbo had a .96 a/r turbine housing.

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Stu
Joined
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21,192 Posts
Discussion Starter #1,603
Had a little time today to get the down pipe modded to fit the GT45 turbo. Not the best of welds but, it will do. Have to add the crankcase evacuation tubes.
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Stu
Joined
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21,192 Posts
Discussion Starter #1,605
The turbo swap is done. Took the 05 for a quick test drive. She spools up quicker now. Feels like it loads up on boost in 2nd gear now. Still a little sluggish on the lower rpm's in 1st gear. The exhaust sound is a little quieter now but, will be removing the 36" Magnaflow muffler for exhaust system mods.
 

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Stu
Joined
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21,192 Posts
Discussion Starter #1,606 (Edited)
The turbo is spooling up quicker but, at the same rpm power band (3000-3200) as the bigger turbo started boosting up at. Trying a few more things but, most likely will have to swap out the stage 4 turbo cam.
 

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Stu
Joined
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21,192 Posts
Discussion Starter #1,609
Have ordered a smaller outside case diameter race muffler to make another tail pipe assembly that will fit with the spare tire in place. Just trying to quiet it down a little and cut out some of the exhaust drone without affecting performance.
 

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Stu
Joined
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21,192 Posts
Discussion Starter #1,610 (Edited)
Installed the smaller outside diameter (6 inch) Dynomax as a tail pipe muffler. Got it to clear the spare tire. Also added a small outside diameter glass pack (5 inch) due to muffler size restrictions in that area. All four diesel performance mufflers are 4 inch in/out now. It feels like it didn't loose any hp/tq this time. Finally happy with how quiet it runs now. (y)
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