Second Gen Swap Kit – what is it? The Second Gen Swap Kit simply means that you change some parts around on your Third Gen Common Rail 5.9 (2003-2007) so that the turbo is mounted centered in the same location as it did in a Second Generation truck from 1994-2002. If you have been intimate with your Third Gen, you know that the stock charger is mounted low and under cylinders five and six. Although this location works and everything fits, it does leave some performance to be gained by changing things up a bit. The Second Gen manifold is divided, meaning the cylinders are paired, 1-3 go to one port, and 4-6 the other. This gives you better performance by matching the exhaust pulses and minimizing turbulence when opposing cylinders are firing. Additionally, by running a center mounted turbo, you will have equalized drive pressures leading to a more balanced Exhaust Gas Temperature.
The kit begins by center mounting the turbo using a divided T3 OE manifold from the 1998-2002 24 valve truck in conjunction with Borg Warner’s S300 SX-E turbo line. Your choice of SX-E turbos are teamed with AGP’s .80 A/R, or 14cm, non-gated divided T3 turbine housing for the best spoolup and airflow available in a T3 configuration. We tap the exhaust manifold for EGT and Drive Pressure monitoring, simply remove the preinstalled plugs and thread in your favorite sensors.
We include an aluminum 4” short ram air intake for the turbo combined with a huge S&B filter so every bit of air makes its way to the turbo. The exhaust exits via our 4” diameter stainless midpipe which ends in the stock location for the 04.5-07 trucks. (Note: The 03-04 application will need a downpipe from 04.5-07 which we can supply in 4” or 5”.) All silicone couplers, clamps, gaskets, oil lines, and hardware is included in this kit for a simple installation.
We offer mirror polishing on the compressor housing and ceramic coating on the manifold, turbine housing, and midpipe. The polishing is for looks and the ceramic coating is for looks and performance. Although we’ve never been able to run a measurable back to back performance test, the drop in underhood temperatures when the exhaust components are coated provides a cooler charge air which leads to denser airflow and cooler EGTs in theory.
What turbo should I choose? This becomes the million dollar question and one that keeps you up late nights losing sleep over. If you have a manual truck, we are always going to recommend the smallest turbo we offer, which would be a 61-65. If your truck is an auto, most setups we'll recommend a 62-68. I know we sound like a broken record when every recommendation ends with "62-68-14", but it's the truth. Our opinion 90% of trucks will run amazing with this kit and a 62-68, even when towing, so that's why we recommend it. Now, if you've got a stroker CP3, large injectors, and an aggressive custom tune from your favorite tuner, we can move up in sizes.