There’s no arguing that trucks today are more powerful than ever before, while also making huge strides in efficiency and emissions. Modern engine management and precision fuel injection is a huge part of that, but one of the biggest leaps forward in the past 20 years has been the proliferation of variable-geometry turbochargers.

A variable-geometry turbo (VGT) has movable vanes inside the exhaust housing that can close up to reduce the A/R ratio and spool the turbo faster. As boost pressure increases with engine speeds, the vanes begin to open up so the increased flow of exhaust gases can spin the turbo at higher RPMs, creating more boost and more top-end power. This best-of-both-worlds approach allows the engine to respond more precisely to throttle inputs, giving you the responsiveness of a small turbo and the top-end power of a larger one.

The downside of trucks with a VGT is cost and complexity. Replacement variable-vane turbos are expensive, not to mention the initial purchase price of the trucks and engines they are attached to. Many of them also require a complicated electronic actuator attached to the turbo, that can only be programmed using proprietary software – not particularly DIY friendly, and it can even be a stretch if you are the in-house mechanic for a small fleet.

Switchblade Turbochargers offer a simplified VGT mechanism that can be retrofitted to pre-emissions engines and pre-VGT trucks, offering the same benefits on the machine you already own. Rather than a series of small VGT vanes that can get choked up one by one with carbon buildup, the Switchblade Turbo has a single vane with a prescribed range of motion. And rather than a computer attached to the turbo that can only be diagnosed or programmed by the dealership, the Switchblade is actuated by a simple pneumatic ram cylinder, like a wastegate actuator. You don’t even need to plumb an extra vacuum line, since the Switchblade actuator reads vacuum pressure from the turbo’s own compressor housing.

Owner/operators who’ve installed the Switchblade Turbo on their machines report better performance and increased fuel economy at the same time. Others have noted a cleaner exhaust (no more black smoke) and increased engine oil life as well.

Switchblade offers this upgrade for a variety of applications, but the most popular units that we keep in stock are built off the frame of the versatile BorgWarner 171702. This turbo is already a common upgrade – it’s found on some high-power variants of the Detroit Diesel Series 60, but is also a bolt-on upgrade for some CAT 3406 and Cummins N14 applications as well – the standardized T6 exhaust flange and infinitely adjustable compressor housing make it easier to fit on a variety of engines. We currently offer two versions of this Switchblade turbo:

75mm Compressor Wheel, rated for up to 500hp: New 75mm Switchblade Turbo For Detroit Diesel Series 60 CAT 3406 & Cummins N14 TUR-106054-SBN

78mm Compressor Wheel, rated for 500-600hp: New 78mm Switchblade Turbo For Detroit Diesel Series 60 CAT 3406 & Cummins N14 TUR-106055-SBN

In addition to these replacements, Switchblade also offers turbos that support higher horsepower engines, as well as options for Caterpillar ACERT and Cummins ISX15. These options may require further modifications, so for those applications, we recommend you contact Switchblade directly for personalized assistance.

Switchblade Turbos provide a way to take advantage of one of the biggest technological advancements in Diesel history (the VGT system) and retrofit it to the pre-emissions trucks that have a bulletproof dependability record. This moderate investment can pay off in both performance and fuel economy, breathing new life into old trucks. Contact us or contact Switchblade Turbo directly (and tell them we sent you!) for knowledgeable assistance getting the best replacement turbocharger for your equipment.