This is a strictly informational post for those of you looking to put a 3rd gen charger on a 2nd gen truck. I was not as prepared for this as I usually am with my truck upgrades, and I did not see too much info on this topic. So here is a short list of what you will need:
- Clamps for compressor outlet - 2.75" vs 3" on 2nd gens
- Boot for compressor outlet - either custom to adapt to your 3" cold piping or use an IC pipe from a 3rd gen truck
- Downpipe - turbine housing outlet is larger on a 3rd gen charger than the popular HX40, so you will need an adapter or use the stock 3rd gen elbow and modify the stock downpipe. If you use the 3rd gen exhaust components, make sure the downpipe and elbow are from the same year range: 03-04 or 04.5-07. They will not interchange.
In addition to the list above, if you are going to swap to a 3rd gen manifold:
- Oil feed - stock oil feed will reach the 3rd gen location quite nicely. The line simply needs to be swapped end for end - the 90 degree fitting will come off of the oil filter housing, and the straight fitting goes on the charger.
- Oil drain - The charger will sit further to the rear of the truck and will require modification. Cutting the tube and splicing in an appropriate sized piece of hydraulic hose or equivalent will work fine.
- Exhaust - The downpipe will require some shortening and removal of the welded on rod that serves as a hanger.
- Compressor outlet - A shortened version of the 3rd gen IC pipe will work well. (Keep in mind that the outlet of the 3rd gen charger is smaller than the outlet of the 2nd gen as I mentioned above.)
- Intake - The air intake from a 2nd gen will require modification to work properly or complete replacement due to the change in turbo location.
- Coolant pipe - The coolant pipe from the 2nd gen that runs to the heater core will need to be replaced with one from a 3rd gen. All that needs to be done is to cut off the heater core end where the 45 degree bend is and secure it.
Hopefully that answers some questions and prevents :doh:
- Clamps for compressor outlet - 2.75" vs 3" on 2nd gens
- Boot for compressor outlet - either custom to adapt to your 3" cold piping or use an IC pipe from a 3rd gen truck
- Downpipe - turbine housing outlet is larger on a 3rd gen charger than the popular HX40, so you will need an adapter or use the stock 3rd gen elbow and modify the stock downpipe. If you use the 3rd gen exhaust components, make sure the downpipe and elbow are from the same year range: 03-04 or 04.5-07. They will not interchange.
In addition to the list above, if you are going to swap to a 3rd gen manifold:
- Oil feed - stock oil feed will reach the 3rd gen location quite nicely. The line simply needs to be swapped end for end - the 90 degree fitting will come off of the oil filter housing, and the straight fitting goes on the charger.
- Oil drain - The charger will sit further to the rear of the truck and will require modification. Cutting the tube and splicing in an appropriate sized piece of hydraulic hose or equivalent will work fine.
- Exhaust - The downpipe will require some shortening and removal of the welded on rod that serves as a hanger.
- Compressor outlet - A shortened version of the 3rd gen IC pipe will work well. (Keep in mind that the outlet of the 3rd gen charger is smaller than the outlet of the 2nd gen as I mentioned above.)
- Intake - The air intake from a 2nd gen will require modification to work properly or complete replacement due to the change in turbo location.
- Coolant pipe - The coolant pipe from the 2nd gen that runs to the heater core will need to be replaced with one from a 3rd gen. All that needs to be done is to cut off the heater core end where the 45 degree bend is and secure it.
Hopefully that answers some questions and prevents :doh: