Flowing More
The stock turbo flows around 750 CFM, whereas the modified Beans version flows more than 1000 CFM. That's a 30 percent increase in airflow, which will improve power output as well as help bring those egts down. Being a direct bolt-in replacement, installation of the turbo is fairly straightforward and can be done out in the garage. This isn't the easiest swap out thereâ_"Ford engineers didn't really think this mounting setup through, so it can be a bit of a pain. But with some patience and time a competent shadetree mechanic can get it done.
Higher egts should be expected when you start fueling the motor heavier, especially on 1994-97 model Powerstrokes that were never intercooled from the factory. So in the quest for cool egts while towing and hot-rodding around town, the installation of a well-performing intercooler system is essential. One of the best options out there comes from ATS Diesel. The intercooler system it offers is a very well-engineered direct bolt-on system that comes with everything required for installation. It was designed to lower the compressed air temperature coming out of your turbocharger by running it through a cooler placed behind your bumper and grille. The cooler the air the better its density, thus maximizing engine performance. ATS says the installation of the intercooler system will drop egts more than 200 degrees F, making it the perfect addition to Project Re-Stroked. The truck is used for towing heavy loads on a weekly basis and cool temperatures while towing is a must, especially if you expect miles of trouble-free performance.
On that note, cool exhaust temperatures are a must for heavy towing. The last thing you want is a set of melted pistons to put on your mantel as a conversation piece. Rear differential heat is also something to keep in mind during heavy towing as well. The heat generated in that rear diff can lead to premature part wear and failure so we looked again to ATS and ordered up one of its HD Differential covers. The HD cover is a heavy-duty cast material for superior strength and increases rear diff capacity by 2.5 quarts. The added fluid capacity will help keep gear oil temps down and keep that ring and pinion happy.
Last but certainly not least, we had to look at improving the exhaust system. When Ford designed this style pickup it didn't really account for the room needed for a free-flowing exhaust. The factory down pipe is a flat, oval-shaped design that runs down between the block and firewall. Removing this very restrictive down pipe for a full 3-inch round version will yield a huge improvement in egts, especially on a truck with modifications like Project Re-Stroked.