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The install wasn't too bad for since I already had the turbo out for a rebuild, among several other things I was working on at the same time. The worst part for me was removing the passengers side connection to the exhaust manifold. I did that side first and just broke the bolts off for removal. I assumed that would be easiest since they are through bolted and the kit came with new bolts. Boy was that mistake, the bolt shank that was seized in the manifold was a bear to remove partly due the limited working space, not to mention the 15 years of rust. Was hard to imagine the smooth shank of the bolt could get that stuck with no threads. What worked on the other side was to spray them down with plenty of Kroil and put a wrench on both the nut and bolt to work them back and forth in the same direction to break the rust bond before breaking them off. Worked like a charm.
I used the Dorman kit as well and had no issues with it.
If your truck lived in the south all of its life like mine did and you remove the turbo, the job is very straight forward and easy to do. If it lived in the north and you try to leave the turbo, pack a lunch and a six pack at least because you will be there a while.
The worst part of the entire job is lining the collector up to the turbo properly, then securing the clamp down. I used a bungee cord to hold the collector in place and then wrestled the clamp into place.
There's conflicting information. In the description on Dorman's web site it says this:
More like a complete kit than a single part, many of our Turbocharger Up Pipes include gaskets and hardware for a complete installation. Tthis part is a direct replacement - exact fit adds efficiency and convenience.
Stainless tubular construction protects against warping or cracking
Precise construction for long-lasting performance
Vehicle try-on testing has been conducted to ensure trouble-free performance
A rigorous quality inspection has been undertaken to ensure high quality
That conflicting info regarding the materials had me scratching my head too. So back in November I sent Dorman an email, Jim S from tech services said the tubes are 409 stainless. Took their word for it but once the pipes arrived I tried a test I know; I swabbed a pipe with lemon juice and did not get the stain/color change typical of mild steel. Not a super conclusive test, of course. Another test would be hit it with a grinding wheel; stainless will spark much less than mild steel. Not really inclined to hit mine with a grinding wheel. Even less conclusive is sticking a magnet on there. Only the higher grades of stainless with more nickel and chrome content are truly non-magnetic. A magnet sticks to the stock stainless exhaust on our trucks to about the same degree as the Dorman pipes.
Given all that I'm confident the pipe is stainless. If the Dormans were mild steel I'd pick the IH in a heartbeat, but given same materials and adequate construction... price wins.
How long did it take you guys to do this? I've got some mild soot, but didn't think it was as big of an issue as it might be.
I'll get a little coal at WOT - more of a black haze. Truck pulls good and gets 15mpg city.
Well, if you remember to pull the intake plenum BOOTS (bottom of spider) and realize you MUST pull the turbo instead of fighting a few hours to get just the right spot....it will be MUCH faster and you aren't as likely to break your EBPV Solenoid.
If you check out my thread linked earlier, scroll through the pics. Installs are around post #63.
I picked up almost 2 PSI of boost across the board. That's over 10%!
That conflicting info regarding the materials had me scratching my head too. So back in November I sent Dorman an email, Jim S from tech services said the tubes are 409 stainless. Took their word for it but once the pipes arrived I tried a test I know; I swabbed a pipe with lemon juice and did not get the stain/color change typical of mild steel. Not a super conclusive test, of course. Another test would be hit it with a grinding wheel; stainless will spark much less than mild steel. Not really inclined to hit mine with a grinding wheel. Even less conclusive is sticking a magnet on there. Only the higher grades of stainless with more nickel and chrome content are truly non-magnetic. A magnet sticks to the stock stainless exhaust on our trucks to about the same degree as the Dorman pipes.
Given all that I'm confident the pipe is stainless. If the Dormans were mild steel I'd pick the IH in a heartbeat, but given same materials and adequate construction... price wins.
400 series stainless is magnetic and will rust. The problem with 300 series stainless is that it grows substantially with elevated temps. The extra nickel and chromium in the 400 is about as good as you can get in this application without going to Inconel or Monel (You think the IH pipes are expensive now? Monel would quadruple that).
I'll take a pic of my sooty up pipe and see what you guys think.