s475 replace s480

TrentNell

Finally underway !!!!!
Jul 7, 2008
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The S480 "should" be a direct drop in , minus going from a 5" inlet to a 5.5" , I have the turbo and the intake adapters needed , if you need anything let me know . If you indeed have a rcae cover it would not even need the adapter , one way to know is pull the intake off and measure it , non race = 5" , race = 5.5" .
 
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HogAssWild

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Nov 12, 2009
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Gotcha. Jag, why do you want to upgrade? Just because? Do you really need more air for a 11.99 pass?? :)

if i got a 11.99 pass i would be happiest man on earth...

anyways.. yeah i jus want to upgrade:Charger:. Like to change it up a bit..

thinkin about a nos kit also:driving:
 
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SDP

AKA Dmax15
Dec 20, 2008
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Port Angeles, WA
You could just machine the cover and add the bigger wheel just another. Option

X2, if you already have the race cover then it can be machined as well as the cartridge to fit the 80mm wheel which is the only difference from 475 to 480 with the 1.32 ex housing.

My guess is that you won't see any benefits doing this with your setup though.
 

othrgrl

Diesel Addiction Owner
Mar 10, 2008
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Wilmington NC
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You could just machine the cover and add the bigger wheel just another. Option

You would need to machine the cover and cut the pocket bigger on the compressor backing plate, then the S480 wheel would fit.

The turbo you are running now is an S475 with a T6 1.32 housing, 96mm turbine, 75mm compressor, and a race cover. The only difference between that and the S480 you are after is the comp wheel and housing. The easiest DIY option would be to buy an S480 race cover and comp wheel, remove your turbo, disassemble it completely, take the center section and new comp wheel to any decent machine shop to cut the pocket bigger, reassemble with the new comp wheel and cover and you will be ready to go. The nut is reverse threaded, when you put it back together use lok-tite and go finger tight then another 90*. The pocket should be the size of the back of the comp wheel + .030" for clearance (.015" all the way around), they will also need to fade the bevel from the new diameter down in. When you put it back together make sure there is no interference between the wheel and the compressor backing plate. I can get you all the parts and a rebuild kit if you want to go back together with new bearings and seals; or you could send me the turbo and I could take care of it all for you and send it back ready to bolt up.

I would also guess that you would see little to no gain. Your stock turbo's turbine is your biggest restriction right now, even at 0% vane position it can't flow the air that the S475 is pushing through your motor. If it was me I would be looking into sticking a nice S300 in there with an HTT stainless housing or a standard housing and big external gate.
 
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HogAssWild

New member
Nov 12, 2009
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You would need to machine the cover and cut the pocket bigger on the compressor backing plate, then the S480 wheel would fit.

The turbo you are running now is an S475 with a T6 1.32 housing, 96mm turbine, 75mm compressor, and a race cover. The only difference between that and the S480 you are after is the comp wheel and housing. The easiest DIY option would be to buy an S480 race cover and comp wheel, remove your turbo, disassemble it completely, take the center section and new comp wheel to any decent machine shop to cut the pocket bigger, reassemble with the new comp wheel and cover and you will be ready to go. The nut is reverse threaded, when you put it back together use lok-tite and go finger tight then another 90*. The pocket should be the size of the back of the comp wheel + .030" for clearance (.015" all the way around), they will also need to fade the bevel from the new diameter down in. When you put it back together make sure there is no interference between the wheel and the compressor backing plate. I can get you all the parts and a rebuild kit if you want to go back together with new bearings and seals; or you could send me the turbo and I could take care of it all for you and send it back ready to bolt up.

I would also guess that you would see little to no gain. Your stock turbo's turbine is your biggest restriction right now, even at 0% vane position it can't flow the air that the S475 is pushing through your motor. If it was me I would be looking into sticking a nice S300 in there with an HTT stainless housing or a standard housing and big external gate.

how much we talkin?

i'm hopin to sell my s475 after i get the 480 to so it wont dig in my pocket to deep plus my truck wont have any downtime...
 

DuramaxPowered

Pushing my luck....
Jan 27, 2008
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Monroe, MI
As Dustin said, your stock VVT is causing the restriction in the system....Ditch the VVT next, I know what I see for drive pressure with the same turbos you have.....
 

othrgrl

Diesel Addiction Owner
Mar 10, 2008
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Dustin im pretty sure he doesnt have a race cover. Its a v-band flange on the compressor outlet.......

What does that have to do with anything? From BullsEye (which is who supplies a lot of the aftermarket turbo guys) the race cover comes with a V-band outlet unless you specify otherwise - I always get them with a 3" hose style outlet so that you don't need any adapters though. The way to tell is like Trent said: 5" inlet = standard cover, 5.5" = race cover.

how much we talkin?

i'm hopin to sell my s475 after i get the 480 to so it wont dig in my pocket to deep plus my truck wont have any downtime...

If you to send it to me I'll get the pocket machined properly, swap on a new S480 wheel, stick on a new polished S480 race cover with the same V-band outlet you currently have (so it will all bolt right back in), and rebuild it with all new bearings and seals. That would run $900 plus the return shipping, and that would be me sending you back your S475 wheel and cover for you to sell. We could also work something out for me to keep your S475 wheel and cover.

Long time Dustin lol havnt seen u on here in a while. Srry back to the thread

Been busy, which reminds me I need to get back to the truck on the lift now.....
 

TrentNell

Finally underway !!!!!
Jul 7, 2008
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IMOP its always cheaper to sell a charger and buy new than convert , yes it does make it bolt in to get your current charger turned into a 480 , and the price Dustin listed is on par with what it cost to do the work , but you could sell your S475 for 500-600 used plenty easy with the polished cover ( maybe race ) and only have to pony up 5-7 bills for a brand new 480 and a intake adapter .
 
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duratothemax

<--- slippery roads
Aug 28, 2006
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Wyoming
ok I was incorrect with that...Forced Inductions told me that the only way to get the 480 was normal cover-V band, and race cover, slip fit.

ben
 

othrgrl

Diesel Addiction Owner
Mar 10, 2008
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Wilmington NC
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I'm lookin at around 3grand for a htt and install kit right?

I haven't been doing full HTT turbos lately. After a 3 month old turbo had a bearing failure which then cause damage to wheels and comp housing with only 3,000 miles; then they refused to cover anything under warranty I don't really like to give them my business. I installed an aftermarket oil pressure gauge on the truck, checked for adequate oil flow from the supply line, and checked for boost leaks - after all that they told my customer to send it in that it would be covered. After it got there they decided not to cover it and charged much more than I would have to rebuild it with better parts.

Anyway, what I do now is get the HTT stainless housing (since that's the only thing special about an HTT turbo) from them and then get the rest of the turbo from my normal source. This way even with a race cover (which doesn't come on the HTT) you end up with about $200 less in it that a full HTT and I know that my supplier will stand behind the bearings and I haven't had problems with theirs to begin with.
 

custom8726

Active member
Feb 25, 2008
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I'm lookin at around 3grand for a htt and install kit right?

I beleive you can find them for closer to $2,700 - $2,800, Check around for pricing, I know Dustin is reasonable on pricing and will be able to give you what ever tech support you need. I have had good luck with Matt at Gillet Diesel aswell.. :thumb: