Join Date: Dec 2006
Location: Palmer, Massachusetts
Thanked 48 Times in 48 Posts
Yes This can be done I have done it. I took my ’95 and put all the SD stuff you want to put in yours.
1st thing SD turbo sits 2” taller then the OBS turbo, I had a flat bed so I did A 2” cab lift, you will need SD up pipes, Then you will need a van intake manifold “Y” pipe. The ’94-’96 intake plenums are 2”, The ’97-’03s are 3”. I suggest getting the 3” intake plenums. I used rubber bushing on mine. For the down pipe I ended up using the flange off of a SD down pipe welded to an aftermarket 3” 2 piece OBS down pipe. IMO using the SD Turbo, up pipes, intake plenums, hybrid down pipe is a good idea if you’re willing to lift your body or seriously pound the fire wall in with a BFH.
The van Powerstrokes have no intercooler, If you are going to run an intercooler then use the SD intake spider.
The OBS turbo has a 1.15 A/R (Area over Radius, Google it) exhaust housing non waste gate and the SD has a .84 A/R waste gated exhaust housing. Basically the SD turbo has less area between the housing and the drive wheel (turbine), The smaller A/R the faster the turbo will spool and it will flow less exhaust. I think the drive wheels are the same, I also believe each turbo has the same internals in the center section. On the compressor side the SD turbo is much more efficient, in fact it is so efficient that the SD trucks “turbo surge” when you chip them with a stock turbo.
The real difference between the OBS and SD HPOP is the OBS has a 15* angle pump gear and the SD has 17* the difference between the pump gear angle is internal, the HPOP drive gear is the same. The OBS HPOP is capable of 2800psi the SD HPOP is capable of 3200psi and flow more oil. I have put 17* SD pumps on all my OBS trucks this is not an issue. Your stock OBS tunes won’t put the oil pressure much past 2600psi, but if you have a chip or 10k ICP mod, the SD HPOP will help.
Now for the injectors. OBS injectors are 90cc single shot, SD are 140cc Split Shot. The SD split shot tune has a move advanced timing to compensate for the split shot (2 injections per cycle) injections, also split shot injectors use a lot more oil. When you put in the SD injectors your truck will run quieter, will has less turbo lag, more boost, very high drive pressure, higher EGT, and start harder you MPG will go down, and your power will be about the same, all due to a delayed injection and more fuel. If you have a tuner you can custom program and advance the timing 4-6* (I think) you should be fine. Other wise I would not use the SD injectors.
Power Hungry Performance makes custom tunes on a few different platforms, TS 6 position, Edge, and one other. I would call them If you want some custom tunes for this project.
Like I said I did this with 1 of my trucks, I had like 45 psi of boost and the EGTs would go to 1400* because of the delayed timing the fuel was not done burning as the exhaust valve was opening creating to much drive pressure, I only got about 2000 miles out of that turbo, hauling hay.
I would go for everything but the injectors, if you do not do an intercooler you will see difference the power will come on sooner, if you put an inter cooler on it you will still have some turbo lag, but better MPGs, HP and Torque, it will just take a few seconds to come on.
If you really want more fuel 160cc singles are nice but will have high drive pressure and EGTs above 2500rpm with the tight SD turbo. For turbo longevity you want to keep your boost under 30 psi with the OBS or SD turbo.
I got hay
abolish the Federal Reserve, they are the real problem
Vote Ron Paul 2012