Quick How To: 2003 Turbo Swap

I figured I would through in a quick "How To" sort to speak of a mod that I recently did. My factory turbo on my truck just wasn't cutting it so I began to look for a replacement. I found a brand new 2003 factory turbo that was sitting in the plastic taking up shelf space inside a warehouse in Texas. Many do the swap because of the distinct "whistle" that it produces on trucks with a free flowing exhaust. When I did the swap I noticed I had gained 2-3lbs of boost and my throttle response actually increased slightly. So without further waiting, here is my promised quick write up.

The install is fairly simple. All in all it took me and two buddies 3 hours to do, but that was including taking time to talk on the phone and drink a few cold ones. There really are 7 basic steps that you need to complete to do this swap. I would venture to say that anyone with basic knowledge of how to use hand tools can do this in their garage or driveway.

1. Drain coolant from overflow bottle, disconnect the small coolant return hose on the left side and the large coolant supply hose from the bottom of the over flow bottle. Both these hoses are held in place by simple clamps. Then remove the entire over flow bootle. This will give you some more room to work; which on these motors is always a good thing.
2. Because I have an aftermarket intake on my truck it, it took me a little longer to remove it. Due to the sheer size of my intake (AFe Stage II:http://innovativediesel.com/i-961921-afe-pro-dry-s-stage-2-type-si-intake-system-51-80392.html ) it had to be removed to gain enough access to the turbo and pedestal.
3. Un-bolt the turbo from the pedestal. This is accomplished by simply using a wrench/socket and taking out three bolts. At this time, I also disconnected the oil drain tube/branch tube. Becareful not to damage the tube because it is fragile and if it's damaged, you must wait until you visit your local Ford Parts dealer and purchase another before driving. After this is done, you can wiggle the turbo out from the pedestal. This takes some patience because it can easily become frustrating. To help give alittle more space, you can un-clip the cowling that conceals the under hood wiring that runs along the fire wall. It is simply held in by plastic clips and can easily be re-secured.
4. Un-bolt the pedestal. Using the same method as with the turbo. The pedestal is held down by four bolts. After it's unbolted, you can then remove it.
5. Replace the old pedestal with a 2003 model pedestal by bolting it in place with the same four bolts removed from the previous pedestal.
6. Bolt the new turbo in place using the old bolts and re-attach the oil supply tube. Make sure to check the o-ring on the tube to make sure it's in good shape. I went ahead and replaced mine just to be safe, considering they are only a couple cents.
7. Re-install the air intake and over flow bottles and fill with fresh coolant.

Parts Needed:
1. 2003 Turbo and Pedestal
2. 2003 Turbo Parts kit (provides you with new 0-rings, washers, bolts, etc)

Photos:

1. This photo shows the front of my new 2003 turbo:
http://i179.photobucket.com/albums/w289/fordzilla_photos/Truck/turbo004.jpg

2. Exhaust side of the turbo. Note it only has 10 blades which gives it that unique sound:
http://i179.photobucket.com/albums/w289/fordzilla_photos/Truck/turbo001.jpg

3. Comparison between 2005 (Left) & 2003 Turbo (Right):
http://i179.photobucket.com/albums/w289/fordzilla_photos/Truck/DSC02006.jpg

4. Comparison shot of the exhaust sides 05 (L) and 03 (R):
http://i179.photobucket.com/albums/w289/fordzilla_photos/Truck/DSC02007.jpg

5. Comparison of pedestal differences 05 (L) and 03 (R):
http://i179.photobucket.com/albums/w289/fordzilla_photos/Truck/DSC02009.jpg

6. 2005 Turbo removed; close up of 2005 pedestal still on the truck:
http://i179.photobucket.com/albums/w289/fordzilla_photos/Truck/DSC02008.jpg

7. New Turbo and pedestal in place:
http://i179.photobucket.com/albums/w289/fordzilla_photos/Truck/DSC02010.jpg

I hope this very brief and non-formal "How To" can help you guys out who are planning to do this mod.

Overall Assessment: 1-10 Rankings
Difficulty: 4
Time: 5
Satisfaction: 9