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Considering a replacement turbo or exhaust brake? Get both with the BD Howler VGT kit for common rail Dodge 5.9L trucks. Enjoy the drivability a modern VGT turbo has offer. Strong exhaust brake rivals butterfly valve type brakes and generates up to 65psi EBP across a wide rpm band. Comes with full install kit including turbo, BD manifold, plug and play controller kit, and all necessary fittings for a straightforward installation.
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My 2006 dodge ram 5.9l cummins has about 325,000 miles on it and all stock. I have been slowly fixing some of the issues with the cummins engine, and it was time to move to the turbocharger. But I also wanted an engine brake to keep from going through brake pads on mountains. This is the only package with all in one. The turbo spools up quicker, and now there isn't any black smoke at acceleration. All of the parts are high quality. At startup it sounds like a jet engine when it's cold (with the engine brake switch on). The engine brake does a great job and slows down to about 45 mph. One thing I wish the kit had included was the turbocharger supply line (I would have paid more to have this included). Mine snapped. Everything worked at startup and is still working great. Installation instructions are very detailed, and I would highly suggest printing them in color. Here are some hints for installation: -Drain the coolant first! Instructions don't mention this at the beginning. -If your engine has miles like mine, then you know original parts seize/break when removing. Make sure you have an easy out before you start. The allen keyed engine plug that you remove for the engine coolant connection rounded out on me. I had to drill it out and use an easy out. Use grease on the drill bit tip to minimize metal shavings from entering the engine (remove grease and shavings often). -Do not hook up the exhaust pipe or elbow/adapter until the exhaust header is bolted up and the turbocharger is bolted to the exhaust header. -I have an automatic transmission and a 5 inch exhaust. I had to loosen the exhaust clamps and modify the exhaust hanger mount to the transmission bellhousing in order to line up with the turbo. -You're going to need crows foot wrenches/sockets to torque the turbo mounting nuts. -It took me a while to get the turbo oil drain line bolted to the turbo because of the engine mount. One bolt can be installed from the rear side of the engine mount, and the other from the front of the engine mount. I am still getting used to turbo. But the engine warms up quicker, the turbo spools up faster, plenty of air is supplied for complete combustion at all loads, and the exhaust brake works great. The exhaust brake is pretty loud and sounds like fireworks as the turbo winds down. I would highly recommend this package for an upgrade that doesn't require any tuning. I had a blast testing the acceleration and exhaust brake for a day (I had to verify everything works!). My next step is to purchase +60 horsepower injectors. Thanks BD Diesel for the high quality turbo upgrade and great instructions!
This is a must do… was blown away with the increase in power and exhaust brake is amazing. Wish I would have done this mod sooner!
I have a 2005 3500 SB Crew Cab (Purchased new. Clean one owner,) with a 6spd manual and what is called a HO or High Output engine that was only sold with the manual trans. I wanted really good exhaust brakes and this was the purchase to do it. Now look at the review from Joseph T below. His comments on the P0299 error code for under boost apply ONLY when I am running my cruise control. It didn't take me long to figure out that every time I hit Cancel on the Cruise controls, I threw this code and went in to Limp mode. I learned using Cruise was not going to work. Joseph T's notes below explain this is. I do have a programmer but seldom use it. So I will start using it and see if it keeps the Limp mode gremlin away. Then during the winter the Exhaust brakes quit working entirely until late Spring. Temperature related? I don't know so two years later they warrantied the module and sent me another. Note, I drive about 3000-4000 a year on this truck. 2005 with 64k miles when it was installed. I just hit 68k last month (June 2022) so miles should not be an issue with the control module. However you have to love them for replacing a module, free. The only downside is the knowledge of the under boost code, needing a controller, and no no on the Cruise, should be better documented upfront so I didn't have to take my truck in three times to get it fixed. So know this going in and I promise you will love this Howler Kit! These guys are great to work with and really stand behind their products! As does Utah Diesel Center in PG Utah.
First of all this has been the best thing I have done to my 06. Response and power are much better and towing is great. I really do love how much this turbo has done for my truck. Something I was not happy about was before I purchased I was told by a BD salesperson this kit would be great for a bone stock truck, not the case at all. Stock truck does not give enough fuel to spool this thing and when it finally does it makes to much boost and the truck throws an overboost code, that code cuts fuel then that throws an underboost code and your in limp mode pretty much. Was pretty disappointed. Then I called BD tech support and that person was mad I was told it would work on a stock truck. Either way got a programmer and all that is solved. Truck runs great. The only big down side is you lose cruise control essentially. The turbo veins use the throttle position to figure out where they need to be, when you set the cruise the turbo sees no throttle input and the turbo opens up and the truck has a hard time spooling so then exhaust temps rise, especially in the mountains. Not a big problem in the flat lands running empty, but with a load or even in the mountains empty cruise control is gone. Just be aware of those things and you will not regret this kit.
It all started when I needed to replace my rusted out exhaust. I'd been thinking of putting on an exhaust brake so it seemed like the proper time to check that off the list. During my research a buddy mentioned this BD kit. I'd been dreaming of doing the VGT swap since I bought the truck almost 7 years ago but was put off from the idea from my local diesel shop at the time (heard it was a programming nightmare). Fast forward to this year when I discoverd the BD plug and play kit. Excited would be an understatement. I already had a BD exhaust manifold on the truck (which sadly didn't work with the new kit), so I knew mostly what I was getting myself into with the install. For me it was a partial 2-person job; getting that heavy new turbo lined up and mounted to the manifold was not going to happen by myself. Clearance around the 2 bottom manifold studs/nuts was pretty bad and it was difficult to get them tightened. The only other part of the install that gave me grief was putting in the new oil drain tube at the bottom of the turbo as there is very little room to reach up in there; in hindsight I'm not sure if the drain tube actually needed to be replaced or if a new gasket could've been put onto the original one. Out of an abundance of caution I contacted BD towards the end of the install to confirm a wiring question. I've got an 04.5 that was probably built the Friday of Cinco de Mayo so it seems half of the time the truck is configured as an 04 and the other half it's an 05 with some parts out of the scrap bin mixed in. I personally find it very nice that I can get a hold of a real person on the phone. I got transferred to the tech-guy (who was out on lunch when I called but promptly returned my call) and he was quickly able to answer/confirm my question. Starting the truck up for the 1st time everything worked as intended, no codes or warning lights (a rarity for my truck projects). After letting it run at idle for a while and verifying the proper functionality of the exhaust brake I took it out for a drive; it's a very noticeable difference. The truck accelerates faster and the power feels like it is delivered more continuously and consistently. The exhaust brake is great. I've been running the setup for a little over a month and have driven a little over 2000 miles, I haven't seen any discernible changes to my fuel economy in that time. Things to note: - One of the brass fittings for connecting the new coolant lines was the wrong size, thankfully I was able to catch a ride to the local hardware store and remedy the problem for about $5 and an extra 20 minutes. - A note in the directions about draining the coolant would have been nice. I'm sure most people figure that out on their own but I can get "tunnel vision" with projects like this and I don't always do a good job of thinking ahead; I also wasn't sure how much coolant would drain out from the engine block - spoiler alert - it's a lot. - Only other thing that I could ask for would be to have a different switch-mounting option (for the EB) available for the manual transmission folks out there. I think pacbrake has a little mounting pod that will attach to the shifter that works out pretty well, thankfully I've got access to a 3d printer so I was able to rig up my own mount. All in all very happy with the product, thanks BD for making the kit!
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