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Well, we just got back from a 2200 mile trip in our truck.(Colorado to Minnesota) We saw real high EGT's pulling our 5th wheel. It weighs about 7K. We had trouble with the turbo in Nebraska. But many many thanks to Rick H. and his spare turbo, we got back on the road. While we replaced the turbo we gutted the EBPV and put a cat delete test pipe in to lower the EGT's. We were seeing EGT's running high in the 1200+ range. This is running 65 to 70mph. It was hard to keep it lower than 1150. After the mods we saw a slight drop. Maybe 100 degrees. I will be getting a 3" down pipe. This is a 95cc with 3.55 gears. I guess my question is: What do you folks with the older trucks see for EGT's? And what have you done to lower them? I would like to be able to run 70 without have to keep a constant eye on the guages. I know running this kind of heat can not be good for the turbo. Any ideas?

Thanks, Scott
 

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(cool) Air in, air out, and RPMs will help you drop your EGT, assuming you don't want to defuel the truck... Looks like you've got the intake covered, and will soon have the exhaust covered, That should help a little more. Was this running on flat ground?

Only other thing I can think of is RPMs- 3.55s probably leave that engine in the 1800 neighborhood at 70... that's not a whole lot of R's... locking out O/D would probably give you some releif in the EGT department, but its gonna hurt the pocketbook. You could try it, though- just to see if it helps.

Intercooler?
 

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You'll probably get better info in the Upgrades and Aftermarket 94-97 forum. This is mostly a towing forum, not upgrades and mods type discussion. That said, you are heading down the right path. I would put the CAT back on, it most likely won't make a huge difference if it is flowing decently (ie not clogged.) These are designed to flow pretty good. Then you don't have to worry about getting caught in inspection.

Second, the biggest killer is your squashed up downpipe. I can't believe that Ford could not come up with a better alternative to this problem than just smashing the downpipe, but they did it, and it makes a pretty sizeable difference in EGT's when you can easily flow the gasses out the turbo. Your muffler and CAT are supposed to be pretty good on that truck, but you could do a muffler delete or a BTM.

Third, an intake that more easily and readily pulls colder air would help, but ultimately, you need an intercooler. Another wonderful Ford decision was to not include and intercooler in the 94-97 trucks. This would probably help quite a bit.

And if all else fails, you can put a water injector on it, but I doubt you'll need it if you free up the exhaust and intercool it...
 
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