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Dodge Trucks => DIY & Self Help => Cummins DIY's => Topic started by: patracy on June 18, 2009, 01:55:23 am

Title: Heat exchanger relocate - prep work for twins
Post by: patracy on June 18, 2009, 01:55:23 am

I did this in anticipation of installing twins down the road.  First of all you'll need to gather all the parts.  I used about 10ft of 3/8" transmission hose.  Three 1/2" compression to 3/8" npt fittings.  Three 3/8" npt female to 3/8" hose barb fittings (note: my install has only two like this, I had to adapt one since they didn't have all the fittings I wanted). Two 3/8" street pipe fittings.  A couple of hose clamps.  Some Teflon pipe tape. A couple of nuts, bolts, and fender washers.  Around 10' of 5/8" heater hose.  Some tie wraps.  And replacement fluids (ATF and Antifreeze).  Tool wise I used a cresent wrench, ratchet, 10mm socket, 1/2" quick disconnect tool, pliers, screwdrivers, drill, knife, line cutter, and funnel.

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05115.jpg)

First I removed the hard line from the transmission.  Make sure you get plenty of drain buckets.
(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05118.jpg)

Then I popped the quick connect off the hard line that loops back to the cooler.
(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05119.jpg)

I then removed the transmission lines from the exchanger.
(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05120.jpg)

Then you're ready to drop the hard line loop to the exchanger.
(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05121.jpg)

Then I began removing the coolant lines from the exchanger.  I installed a new line in a loop to help cut down on the coolant loss.  Be quick, it comes out quick.  I started with the top line first near the alt.  Then I worked on the lower one near the oil filter.

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05123.jpg)

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05124.jpg)

Then you're free to remove the hard lines under the exhaust manifold.

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05125.jpg)

Then remove the four 10mm bolts that hold the exchanger onto the block and motor mount.  Then you're free to remove the exchanger.

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05126.jpg)

Then I drilled two holes in the mounts for the cooler. 

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05130.jpg)

I removed this rubber section from my truck, part of it was already loose.

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05127.jpg)

I used the line cutter and remove the fittings I needed from the factory lines.   Just tape up the threaded section and install the nipple on it.  Then slide the lines into the compression fittings and tighten them down.

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05131.jpg)

Then I mounted the exchanger to the crossmember.  The great thing is that the crossmember already has holes in it where you can bolt it in place.  Then I installed the fittings.  I made note of how everything flowed prior to relocating it and matched up the lines.

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05135.jpg)

To get the hose on one of the lines from the front cooler I had to remove the three 10mm bolts to allow enough movement.

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05140.jpg)

This is optional, but if you can find about 2' section of 1/2" transmission line.  This would go a lot smoother if you used that line with a 1/2" barb instead.  I just wrestled with it for a while until I got it on and clamped.

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05138.jpg)

Then I threw a few tie wraps on it to keep the lines in check.

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05139.jpg)

Here's the pile o' parts you'll have left over.

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05134.jpg)

Then top off your coolant and ATF fluids.

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05142.jpg)

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05143.jpg)

Then enjoy your newly found space in anticipation of another turbo.

(http://img.photobucket.com/albums/v28/patracy/dodge/DSC05141.jpg)

(Overlook the crack and poorly patched block on my truck.  :argh: )

Title: Re: Heat exchanger relocate - prep work for twins
Post by: Mitch on June 18, 2009, 02:04:56 am

What else do you have in store for us?

Title: Re: Heat exchanger relocate - prep work for twins
Post by: patracy on June 18, 2009, 02:20:56 am

Quote from: Az2500Cummins on June 18, 2009, 02:04:56 am

What else do you have in store for us?

Well I've already played with propane, I've done the HE351 swap.  Studs and springs are next.  I'm thinking I'll build a Water/Meth system next...

Title: Re: Heat exchanger relocate - prep work for twins
Post by: Drew on June 18, 2009, 02:46:32 am

you got a 53 block there???

Title: Re: Heat exchanger relocate - prep work for twins
Post by: patracy on June 18, 2009, 02:51:20 am

Quote from: Drew on June 18, 2009, 02:46:32 am

you got a 53 block there???

Yeah  :argh:

It was cracked when I got it.  Past owner make a plate and welded in to "fix" the leak.  Still had pinhole leaks on the corners.  I just applied a layer of marine tex gray epoxy over it to see if I can get it to stop dripping.

It's got 240K on it.  I'll just live with it.  It's just a matter of refilling every once in a while.  Hopefully my epoxy coat will fix it for me though.