Turbo to manifold gasket?

I've seen this happen when the wrong bolts are used or when drive pressure is up so high it's trying to force the gasket out. Since you have a bridge with a stock ECM and turbo this shouldn't be the problem. Does the truck still have the stock mufflers on it? If so the catylic converters maybe stopped up causing the high back pressure in the exhaust.

You will need to flash the ECM to a 6NZ or 7CZ file if you want to install a BW turbo. I would also remove the mufflers and use Donaldson M100463 in there place to lower exhaust back pressure. The only other thing that maybe creating your problem is the manifold or turbo flange has warped and you're not getting an even crush on the gasket. Go with a PDI manifold instead of a CAT

 

You're getting there.

Yes the CAT bolts are a special heat treated alloy designed for this application. Always use CAT bolts to install a turbo. Once you get the PDI manifold it will come with special studs and nuts to install the turbo.

 

an old boss of mine used non cat bolts years ago and guess what they broke. I would by cat bolts use anti sieze on the threads and install new gasket as stated above, good luck, oh yes check the faces for warp's

 

how does the pdi manifold stand up to the rest? full tilt,pitt power,bully dog,etc....

 

I have a 06 ACERT I've had both the plain and ported/coated PDI manifolds on it. Both are worth the money IMO the plain nonported is the better buy. They are made very well alot better than the oe.

 

If your letting a shop do the refit, be sure to tell them all this too. And a Q: Is 1200 EGT an everyday thing for you or just a rare bird on a hard pull?

 

1200 EGT is hot, but if you're dealing with a stock MBN CAT this is considered normal. In the MBN this heat creates issues with the manifold and turbo after awhile, usually the center sections of both crack and start eroding away

 

Full Tilt, Bully Dog and Pitt Power are selling the same exact manifold with different labeling on it. PDI manufactures their own manifold, I feel the PDI manifold after it's been extrude honed and coated is a better product compared to the BD, FT, and PP ported and coated manifold. The reason I feel this way is the flow is very close in the plenum area between the manifolds, but the turbulence is lower with extrude honing over porting. Lower turbulence in the plenum causes the turbo to respond quicker.