OM606 Thread/Info/Discussion

[87freerunner]

@Dougal I have a td04hl-19t on hand. I also have a Borg Warner s252. Here are the specs for that. Would that work for the secondary turbo?

• BorgWarner s200sx-e (s252)
  • Model: 12709095019
  • Forged milled (billet) compressor wheels with extended tip technology
  • Compressor cover integrated speed sensor port and pre-machined boost port
  • 1/4"NPT oil inlet
  • Oil drain is the standard T3-T4 with M8x1.25 threads
  • Compressor: 52.17mm inducer 69.5mm exducer FMW Forged Milled Wheel (Billet)
  • Turbine: 61mm exducer, 70mm inducer turbine wheel

I am starting my own OM606 swap soon. I picked up a low mile turbo motor locally and will also be running a Borg Warner S200 with the .48 housing. I sourced a 2h bellhousing and accessories so I can use an H55 with my existing split case and run the transmission in the stock location. Ill be using the DPUK H55 adapter. Im in Austin TX and will likely use Benzeforce for the injection pump since I can just run over there and pick it up. I still have a handful of parts needed to start the swap but will hopefully get it going in December. Ill start my own thread but its nice to connect with others doing this swap for information. good luck with yours!

 

[fjdiesel]

I am starting my own OM606 swap soon. I picked up a low mile turbo motor locally and will also be running a Borg Warner S200 with the .48 housing. I sourced a 2h bellhousing and accessories so I can use an H55 with my existing split case and run the transmission in the stock location. Ill be using the DPUK H55 adapter. Im in Austin TX and will likely use Benzeforce for the injection pump since I can just run over there and pick it up. I still have a handful of parts needed to start the swap but will hopefully get it going in December. Ill start my own thread but its nice to connect with others doing this swap for information. good luck with yours!

I agree, it is nice to see what others are doing on the same style swap. I am rounding all the parts together right now to go with twin turbos. It looks like I will be using a td04HL-19t and an HX35. I am going to take off my DPumpUK 7.7mm injection pump and put my stock electronic pump back on and use a DSL1 controller. I can't get the fuel to adjust enough doing elevation changes... Sea level to 13k ft.

 

[davegonz]

I am starting my own OM606 swap soon. I picked up a low mile turbo motor locally and will also be running a Borg Warner S200 with the .48 housing. I sourced a 2h bellhousing and accessories so I can use an H55 with my existing split case and run the transmission in the stock location. Ill be using the DPUK H55 adapter. Im in Austin TX and will likely use Benzeforce for the injection pump since I can just run over there and pick it up. I still have a handful of parts needed to start the swap but will hopefully get it going in December. Ill start my own thread but its nice to connect with others doing this swap for information. good luck with yours!

Let me know when you start. I'm in Austin and would love to check it out.

 

[davegonz]

Has anyone come across an adapter kit to mate an OM606 to H15x transmissions?

 

[87freerunner]

Has anyone come across an adapter kit to mate an OM606 to H15x transmissions?

I believe diesel pump UK has one

 

[fjdiesel]

Started on getting compounds mounted on my OM606.

 

[87freerunner]

Finally got started on my swap. Confirmed fitment of the DPUK adapter to motor and to the 2H bellhousing for the H55. All works well, need to order a starter and install the clutch and I can put the transmission and engine together and get started on mounting it in the truck. The trucks in the background are not mine, but are way cooler projects than my little OM606 swap!

 

[Adam R]

I agree, it is nice to see what others are doing on the same style swap. I am rounding all the parts together right now to go with twin turbos. It looks like I will be using a td04HL-19t and an HX35. I am going to take off my DPumpUK 7.7mm injection pump and put my stock electronic pump back on and use a DSL1 controller. I can't get the fuel to adjust enough doing elevation changes... Sea level to 13k ft.

FWIW, I'm running a TD04HL-19T and an HX35 with my 4BD1T engine. The 4BD1T is a 3.9L medium duty Isuzu truck engine and my max rpm is about 3200, although I rarely run it that high. With this compound setup, I can get 26 lbs of boost at 1600 RPM and my EGT's max out at 1250F. Max boost I've run is 34 lbs. I've never been totally happy with this engine as it's a big 4 cylinder and it's not exactly silky smooth, although it's better than the 4BT. I will admit, pulling passes in Colorado at 70 mph is quite nice. I'm considering dropping in an OM606 with a 603 pump and mating it to the 4L80E that is already behind the Isuzu. For the time being, I'm just lurking....

 

[fjdiesel]

FWIW, I'm running a TD04HL-19T and an HX35 with my 4BD1T engine. The 4BD1T is a 3.9L medium duty Isuzu truck engine and my max rpm is about 3200, although I rarely run it that high. With this compound setup, I can get 26 lbs of boost at 1600 RPM and my EGT's max out at 1250F. Max boost I've run is 34 lbs. I've never been totally happy with this engine as it's a big 4 cylinder and it's not exactly silky smooth, although it's better than the 4BT. I will admit, pulling passes in Colorado at 70 mph is quite nice. I'm considering dropping in an OM606 with a 603 pump and mating it to the 4L80E that is already behind the Isuzu. For the time being, I'm just lurking....

That sounds interesting. What vehicle is it in? Any pics of the setup?(EDIT, I see it in an 80 in your signature)

I built an FJ60 15 years ago with a 4BDT2 in it. I used the Super HX30W. I had done an in frame rebuild with new sleeves. Had the pistons and rods balanced. That thing pulled like a freight train and was soooo smooth. With that turbo and the pump turned up, I was at about 220 HP. Not bad on a stock 130 HP motor.

 

[Adam R]

Also, I was re-mis in giving credit to Dougal. He was on the 4BD1T forums providing advice and guidance on my build 12+ years ago. Glad to see he's still passing on his sage advice. - Adam

 

[msods]

Finally got started on my swap. Confirmed fitment of the DPUK adapter to motor and to the 2H bellhousing for the H55. All works well, need to order a starter and install the clutch and I can put the transmission and engine together and get started on mounting it in the truck. The trucks in the background are not mine, but are way cooler projects than my little OM606 swap!

View attachment 4053029View attachment 4053030View attachment 4053031

This is awesome. Hopefully I see it driving around Austin here in a few months

 

[87freerunner]

This is awesome. Hopefully I see it driving around Austin here in a few months

Just test fit the engine this past weekend, working on motor mounts now. My goal is to have the engine work finished up and ready to drop in before March. I have two weeks off work over spring break and hope to finish up as much as possible and maybe have it at least running in the truck by then.

 

[Mustardmafia40s]

Just test fit the engine this past weekend, working on motor mounts now. My goal is to have the engine work finished up and ready to drop in before March. I have two weeks off work over spring break and hope to finish up as much as possible and maybe have it at least running in the truck by then.

Im currently gathering parts to swap a ‘99 om606 into my 1980 HJ45 Troopy (H diesel). I’m only planning on using one turbo due to my truck being RHD, but I’d go the twin turbo route also if not for the interference of the steering column. I’ve been lurking and following your progress for a while now and I still need to collect a few more parts, but I’ll soon be ready to start putting this thing together. I’m curious as to what clutch you went with (2H?) and what year transfer case you’re using with the H55f? Thanks and I look forward seeing your continued progress.

 

[87freerunner]

Im currently gathering parts to swap a ‘99 om606 into my 1980 HJ45 Troopy (H diesel). I’m only planning on using one turbo due to my truck being RHD, but I’d go the twin turbo route also if not for the interference of the steering column. I’ve been lurking and following your progress for a while now and I still need to collect a few more parts, but I’ll soon be ready to start putting this thing together. I’m curious as to what clutch you went with (2H?) and what year transfer case you’re using with the H55f? Thanks and I look forward seeing your continued progress.

I’m using the sachs racing clutch that came with the adapter plate kit from DPUK. Using the original tcase from the 1990 fj62. I had recently rebuilt it with new bearings so I just needed the gasket kit this time around for reassembly. I also have the longer splined output shaft gear to not tear up the splines on the output shaft to handle the increased power and torque

 

[Mustardmafia40s]

I’m using the sachs racing clutch that came with the adapter plate kit from DPUK. Using the original tcase from the 1990 fj62. I had recently rebuilt it with new bearings so I just needed the gasket kit this time around for reassembly. I also have the longer splined output shaft gear to not tear up the splines on the output shaft to handle the increased power and torque

That’s interesting and good info. I have a’87 fj60 t case, but I’m not sure if it’s the same as the one you have. What year(s) was the longer output shaft used in? I plan on having somewhere around or just below 300 hp, but the longer / sturdier shaft sounds like a good idea.

 

[87freerunner]

That’s interesting and good info. I have a’87 fj60 t case, but I’m not sure if it’s the same as the one you have. What year(s) was the longer output shaft used in? I plan on having somewhere around or just below 300 hp, but the longer / sturdier shaft sounds like a good idea.

Sorry, I re read my explanation and realize it wasn’t very clear! The OEM output shafts are the same, it’s the gear that can be an issue. The OEM output shaft gear in the tcase is usually a thinner gear with a spacer, so the gear is only grabbing a small amount of the output shaft splines. That can wear down the splines on both the shaft and gear. Georg at valley hybrids sold me on the longer splines gear, it’s basically the gear and spacer all in one piece so it grabs more of the output shaft splines and distributes the torque over more area causing less wear. I’ll share some pics of the old shaft and gear vs new.

Old gear vs new gear

Old gear spline wear

Output shaft spline damage on the old auto transmission.

New H55 plus the larger gear should eliminate any of these problems. This is why a lot of the fj62’s have a nasty clunk when going into reverse, too much play in the splines.

 

[Mustardmafia40s]

Sorry, I re read my explanation and realize it wasn’t very clear! The OEM output shafts are the same, it’s the gear that can be an issue. The OEM output shaft gear in the tcase is usually a thinner gear with a spacer, so the gear is only grabbing a small amount of the output shaft splines. That can wear down the splines on both the shaft and gear. Georg at valley hybrids sold me on the longer splines gear, it’s basically the gear and spacer all in one piece so it grabs more of the output shaft splines and distributes the torque over more area causing less wear. I’ll share some pics of the old shaft and gear vs new.

Old gear vs new gear
View attachment 4093407

Old gear spline wear
View attachment 4093406

Output shaft spline damage on the old auto transmission. View attachment 4093408

New H55 plus the larger gear should eliminate any of these problems. This is why a lot of the fj62’s have a nasty clunk when going into reverse, too much play in the splines.

Ah yes, pictures make all the difference for me when I’m learning stuff. I see exactly what you’re talking about. As I go along, I may reach out to you occasionally because I’m sure there will be some sticking points for me. I would love to have this swap completed by the end the coming summer because this is our fall camping vehicle, but I don’t know if that’s a realistic goal or not. I’ll try not to be too much of a pain by asking a bunch of dumb questions, but I really appreciate you replying. I know way more than I did. Thanks and keep us updated

 

[87freerunner]

Ah yes, pictures make all the difference for me when I’m learning stuff. I see exactly what you’re talking about. As I go along, I may reach out to you occasionally because I’m sure there will be some sticking points for me. I would love to have this swap completed by the end the coming summer because this is our fall camping vehicle, but I don’t know if that’s a realistic goal or not. I’ll try not to be too much of a pain by asking a bunch of dumb questions, but I really appreciate you replying. I know way more than I did. Thanks and keep us updated

Happy to help if I can, but am definitely also learning along the way! dont hesitate to reach out!