Htt stage3 kit for HX35's - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 12 (permalink) Old 09-24-2005, 08:02 PM Thread Starter
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Htt stage3 kit for HX35's

Install of HTT's stage3 kit for HX35, also available for HY35 and WH1C
(Wrench or socket size in parentheses)
What this kit is: upgrades your existing 54 or 56 mm intake impeller to a 60mm one.
What youíd expect to gain from it: #1 reason is lower EGTís, itíll better support up to 350 hp, and provide a little more air for higher rpm. If you drive without a silencer ring this will be a little louder, but itís not ear piercing.
We'll start by pulling off the intake hose from the turbo. Then remove the band clamp from the exhaust side. Now remove the pressure line (5/8 & 3/4"or 16&19mm), return line (10mm) and mounting bolts (15mm) and it's ready to come out. You may have to remove the air filter box if you still have one.
Before taking it apart, it may be a good idea to mark the exhaust & intake housing in relation to the turbo body to ease bolting it back onto the truck.
You may need to spray penetrating oil on the bolts to get the turbine housing off. Now take off the 4 bolts (13mm) for the exhaust housing, you may have trouble with one of them. Take out that one as far as you can, then some wiggling or gentle hits with a soft blow hammer, try to get that housing off. Be careful, because at the last second it'll pop off and you don't want to damage the impeller. Once it starts coming out you should be able to get that last bolt out, then the housing will come off.
Now, a big snap ring around the outer edge of the compressor housing holds on the intake side on the í35, and a screw type clamp for a WH1C. I had to use channel locks, or 'water pumps' to stretch across the tabs on the ring. It wiggles off much easier than the exhaust side. Now a socket on the intake impeller/compressor wheel nut (12mm), and one on the exhaust impeller nut (13/16Ēor 20mm) and take off the nut on the intake side (donít forget it's reverse thread). The impeller slides right off, then there's a mental note to make. As you take off the compressor wheel you'll see how it's inset in the body of the turbo. The outer edge of the little lip is what needs to be machined out to accept the bigger wheel. You can also send yours in to HTT to have them machine it for this, or do the whole stage3 kit.
Next is to slide out the shaft by pulling the exhaust impeller, because it gets in the way of the machinist. Itís now ready to take to the shop to have that inset groove enlarged to 3.420Ē, which is .030 larger than the wheel. You might want to plug up the holes where the shaft was to keep some of the machining shavings out. This is also the time to inspect for wear. Mine had blue spots on the seal plate and thrust collar, and I had to order new ones. It also may be a good idea to have the shop check the shaft to make sure itís straight

Once you get the body back from the shop, you can start by cleaning the inside where the shaft was. Even if it was plugged up it wont hurt to err on the cautious side. WD40 is cheap and effective here. Use liberal amounts to flush all the particles out. Now put a little engine oil on the shaft and inside the body, and slide it in. Add the new stage3 impeller and torque the nut according to the nut you have. Thereís different specs, the 6 point nut goes to 120 inch pounds, and the 12 point goes to 100 inch pounds. Then, install the exhaust housing, retainers, and 4 bolts. Leave the bolts a little loose in case you need to clock it during reassembly.

Start out by putting the big snap ring over the top of the body. Put the new Stage3compressor housing (lined up as the old one was) on the compressor body. Then as an assembly, flip it over so the inlet is facing the floor. Grab the pliers used to remove the snap ring; itís going to be a fight to compress it to fit inside the lip of the compressor housing. I had to use my knee to push down on the body while my left hand held the snap ring down. My right hand was trying to get the snap ring on before it popped off the pliers. This is where I got really frustrated; it took me a good 45 min. to get it together. That was the hardest part. Just assemble it like it was taken off, and youíre ready to fire it up. Check for leaks and all that good stuff, then go for a spin.

Pic#1 is the stage3 impeller on the right and the stock on the left.
Pic#2 is after the shaft comes out throught the exhaust side. A peek at the journal bearing.
Pic#3 is what's behind the seal plate(mine was burnt from making contact because of a bent shaft)
pic#4 is after I got the turbo body back from the machine shop with its new inset surface of 3.420"
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Dale

my daily driver:67 F100, 300 4V, cammed, 4 spd.
or, 08 Subaloser Forester, 2" lift.
work rigs: 94 IH 4900, DT466(originally 230hp), #0 fuel plate, tighter gov springs, 22* timing
or, 06 IH 7400, DT466E, 300hp


My Low Buck fuel rate site:
www.freewebs.com/nevrenufhp
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post #2 of 12 (permalink) Old 09-24-2005, 08:03 PM Thread Starter
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Pic#1 is with my new seal plate and thrust collar, ready for the new Stage3 impeller.
pic#2 is the impeller mounted and exhaust housing on, ready to put on the compressor housing.
pic#3 is up close of the stage3 compressor housing to note there's no provision for a silencer ring.
pic#4 is the under side of the compressor housing & the slot where the big snap ring goes
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Dale

my daily driver:67 F100, 300 4V, cammed, 4 spd.
or, 08 Subaloser Forester, 2" lift.
work rigs: 94 IH 4900, DT466(originally 230hp), #0 fuel plate, tighter gov springs, 22* timing
or, 06 IH 7400, DT466E, 300hp


My Low Buck fuel rate site:
www.freewebs.com/nevrenufhp
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post #3 of 12 (permalink) Old 09-24-2005, 08:04 PM Thread Starter
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The finished product:
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Dale

my daily driver:67 F100, 300 4V, cammed, 4 spd.
or, 08 Subaloser Forester, 2" lift.
work rigs: 94 IH 4900, DT466(originally 230hp), #0 fuel plate, tighter gov springs, 22* timing
or, 06 IH 7400, DT466E, 300hp


My Low Buck fuel rate site:
www.freewebs.com/nevrenufhp
nevrenufhp is offline  
post #4 of 12 (permalink) Old 07-06-2009, 09:13 AM
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nice write up

Greg aka Cumminsproud

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96 Ram 3500 Slt Ext Cab 12v cummins nv4500 afc housing and plate full forward with 4in exhaust and k&n drop in and smoke screw turned in a few turns it wants to be a 2.6 truck

94 Ram 2500 Slt Reg Cab 12v cummins auto: custom grind fuel plate, afc housing ff, afe stage 2 bhaf, mbrp 4in str8 pipe exhaust, 3k gsk, isspro gauges trans, egt, and boost, 20in Moto Metal punishers on 33's -let the smoke start rollin

new truck 96 p pump 24v
floor it diesel performance and raw diesel performance all the way

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post #5 of 12 (permalink) Old 07-08-2009, 09:48 PM
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i'm looking to do this wih my new turbo

Greg aka Cumminsproud

Go Clemson Tigers Football

96 Ram 3500 Slt Ext Cab 12v cummins nv4500 afc housing and plate full forward with 4in exhaust and k&n drop in and smoke screw turned in a few turns it wants to be a 2.6 truck

94 Ram 2500 Slt Reg Cab 12v cummins auto: custom grind fuel plate, afc housing ff, afe stage 2 bhaf, mbrp 4in str8 pipe exhaust, 3k gsk, isspro gauges trans, egt, and boost, 20in Moto Metal punishers on 33's -let the smoke start rollin

new truck 96 p pump 24v
floor it diesel performance and raw diesel performance all the way

Bracken Pullin Team 2008-2010 MSTPA Points Champions

SINGLES CLUB # 210 former
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post #6 of 12 (permalink) Old 07-28-2009, 11:26 PM
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does it need to be balanced after reassembly?

Garrett






BRING BACK THE OLD TDG!
oh well, i have a map to the darkside

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post #7 of 12 (permalink) Old 07-28-2009, 11:30 PM
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Damn!! I need to stop looking at upgrade threads!!

-Josh-
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post #8 of 12 (permalink) Old 07-28-2009, 11:41 PM
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Quote:
Originally Posted by BombDocDiesel View Post
Damn!! I need to stop looking at upgrade threads!!
haha, and i need to stay out of the classified threads too.

Garrett






BRING BACK THE OLD TDG!
oh well, i have a map to the darkside

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post #9 of 12 (permalink) Old 07-29-2009, 05:57 PM
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ha ha i need to do both so i can have some money

Greg aka Cumminsproud

Go Clemson Tigers Football

96 Ram 3500 Slt Ext Cab 12v cummins nv4500 afc housing and plate full forward with 4in exhaust and k&n drop in and smoke screw turned in a few turns it wants to be a 2.6 truck

94 Ram 2500 Slt Reg Cab 12v cummins auto: custom grind fuel plate, afc housing ff, afe stage 2 bhaf, mbrp 4in str8 pipe exhaust, 3k gsk, isspro gauges trans, egt, and boost, 20in Moto Metal punishers on 33's -let the smoke start rollin

new truck 96 p pump 24v
floor it diesel performance and raw diesel performance all the way

Bracken Pullin Team 2008-2010 MSTPA Points Champions

SINGLES CLUB # 210 former
DUALLY CLUB # 92 Wide Body Status
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post #10 of 12 (permalink) Old 07-30-2009, 12:25 AM
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I wasn't even commenting on Classifieds. Maybe I need to move the other scoot and trailer.

-Josh-
"SLICK" 2008 Chevrolet 2500HD LT 4X4 Z71 CC/SB D/A Silver Birch Metallic

My Gassers
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Are you thinking about a Duramax? You need Duramax Info! The Duramax Index

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