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Direct replacement aftermarket turbo frame PT5557

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Direct replacement aftermarket turbo frame PT5557

Old 07-04-2019, 06:31 PM
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Direct replacement aftermarket turbo frame PT5557

I am currently running a Precision 5557 w/ T3 inlet .63 turbine and looking for a direct swap replacement to bolt-on (except I would like to go with a 1.06 AR 3" V-band outlet instead of the 5-bolt 2.5" outlet). Will a T3 BW S256SX bolt-on in place of the 5557? The large A/R is because I am twincharged.


My fresh rebuilt Precision 5557 turbocharger is leaking oil on the hot side and I just found unacceptable shaft play so it's gotta go. This was rebuilt by Precision and has less than 1,500 miles on it, I plan on sending it back to Precision to check out why it failed. I am running a purchased/assembled -3AN direct oil line from the oil cooler Tee'd off sharing the T with the oil pressure sensor and I have been monitoring oil pressure constantly, so there is high confidence there is not an oil feed problem. I am also running a -12AN oil drain full flow there are no 'fail' adapters or transitions that bottle neck the inside diameter. I have higher than normal blowby but I do have a 5/8" bung on the valve cover that goes directly to the bottom end of the crankcase.
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Old 07-04-2019, 08:09 PM
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im not sure about the gen 3 blocks, but the gen 1 and 2 blocks the oil pressure sensor is oil from between the pump and filter, so on those its not filtered oil. i like to feed my turbo with oil from above the balance shafts, however i dont think the gen 3 block has those ports. i also like to use a -4 line to feed the turbo.

im wondering if you wouldnt benefit from going to a larger compressor. do you by chance monitor boost pressure between the turbo and the blower? one thing i see everyone doing on twincharged setups on these cars is going with the same size turbos that are commonly run on a turbo only setup, and thats not typically how a compound setup works best.
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Old 07-05-2019, 11:15 AM
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Originally Posted by Sharkey View Post
im not sure about the gen 3 blocks, but the gen 1 and 2 blocks the oil pressure sensor is oil from between the pump and filter, so on those its not filtered oil. i like to feed my turbo with oil from above the balance shafts, however i dont think the gen 3 block has those ports. i also like to use a -4 line to feed the turbo.

im wondering if you wouldnt benefit from going to a larger compressor. do you by chance monitor boost pressure between the turbo and the blower? one thing i see everyone doing on twincharged setups on these cars is going with the same size turbos that are commonly run on a turbo only setup, and thats not typically how a compound setup works best.
I am running the ecotec remote oil filter adapter to run a remote filter and oil cooler, the pressure sensor and oil feed is on the return line back to the engine.

The car is still being tuned, the max boost so far at the engine is about 28 psi and about 18 psi out of the turbocharger. There are some packaging challenges, life would be cheap and easy to keep the 3" compressor inlet so looks like that is limiting factor and same with the exhaust side my turbo manifold is custom with a T3 flange so that is not going to change either.
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Old 07-09-2019, 10:57 AM
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I contacted AGP, the S256SX will bolt-on.

As far as the turbo, it's "rated" for 495 bhp but I was running about 525 bhp and with the small 0.63 A/R I was probably over spinning the it...so this might be expected. The 5557 is a weird on, I asked Precision when I was getting it rebuilt if I could upgrade the turbine to a larger A/R, they said it is actually a turbonetics turbo and gave me contact info for them.

I assume going to a 1.06 A/R would reduce turbo speed for the same amount of flow. Any thoughts on that?
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Old 07-09-2019, 11:01 AM
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Im pretty sure compressor flow is proportional to turbine speed. The point of going to a larger turbine housing allows more exhaust flow because the internal volume is larger.
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Old 07-09-2019, 11:03 AM
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If youre going to change turbos and plan on keeping the blower, you should step up to a 363sxe. Youll be able to flow much more at a lower boost pressure and still have good response because of the blower.
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Old 07-09-2019, 01:37 PM
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Originally Posted by Slowbalt2000 View Post
If youre going to change turbos and plan on keeping the blower, you should step up to a 363sxe. Youll be able to flow much more at a lower boost pressure and still have good response because of the blower.
Problem is the compressor housing looks way bigger on the 363, no way it would fit =(


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Old 07-09-2019, 01:41 PM
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Make it fit.
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Old 07-09-2019, 02:48 PM
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Originally Posted by Slowbalt2000 View Post
Make it fit.
I do want to fabricate a custom exhaust manifold...when I retire! Some guy at work says a HX35 or H1C might work, he is going to do government work on it so he is bringing it by tomorrow so I can put it next to the 5557 and see what it looks like. Compressor maps for those diesel turbos show up to 70 lbs, where the 256 is around 55.
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Old 07-09-2019, 03:09 PM
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Originally Posted by Slowbalt2000 View Post
If youre going to change turbos and plan on keeping the blower, you should step up to a 363sxe. Youll be able to flow much more at a lower boost pressure and still have good response because of the blower.

i agree. unfortunately precision doesnt map their turbos so its really hard to tell where the turbo is in its efficiency. 18psi from the turbo isnt much, but you need to consider the total airflow of the engine as thats whats flowing through the turbo. you are likely over 60 lb/min of airflow, and that puts that 5557 way outside the efficiency (from numbers im able to find, they may not be correct). at least with the borg warner turbos you can look at compressor maps, play around with numbers and try to sort out what would be best.

going with a larger exhaust housing will reduce turbo drive pressure, it wont necessarily slow the turbo down it just allows more exhaust flow. this will make the engine happier as your pushing a lot of air through a tiny exhaust housing. a t4 inlet would be even better, but i understand the reasons not to change what you have.

my opinion is the s200 is too small to efficiently do what you are trying, but if you have to stick with that frame size i would go with the largest compressor they make, the s257sxe
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Old 07-09-2019, 03:36 PM
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I dont think an hx35 is really any bigger than a 5557. Didnt zzp back in the day make an s262? Compressor probably still wouldnt fit. Whats the clearance issue with the manifold?
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Old 07-09-2019, 04:00 PM
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Originally Posted by Slowbalt2000 View Post
I dont think an hx35 is really any bigger than a 5557. Didnt zzp back in the day make an s262? Compressor probably still wouldnt fit. Whats the clearance issue with the manifold?
The head are pretty tight. I would need to move the position of the turbo or put it though the hood. Also not sure if they make an air filter for a 4" compressor inlet with a 5" base, but I guess I could smash the air filter into place though but would prefer not.

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Old 07-09-2019, 04:26 PM
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Originally Posted by Sharkey View Post
i agree. unfortunately precision doesnt map their turbos so its really hard to tell where the turbo is in its efficiency. 18psi from the turbo isnt much, but you need to consider the total airflow of the engine as thats whats flowing through the turbo. you are likely over 60 lb/min of airflow, and that puts that 5557 way outside the efficiency (from numbers im able to find, they may not be correct). at least with the borg warner turbos you can look at compressor maps, play around with numbers and try to sort out what would be best.

going with a larger exhaust housing will reduce turbo drive pressure, it wont necessarily slow the turbo down it just allows more exhaust flow. this will make the engine happier as your pushing a lot of air through a tiny exhaust housing. a t4 inlet would be even better, but i understand the reasons not to change what you have.

my opinion is the s200 is too small to efficiently do what you are trying, but if you have to stick with that frame size i would go with the largest compressor they make, the s257sxe
That 257 looks like it would work has a 2" outlet, map shows 65 lbs flow: https://www.theboostlab.com/s257-sx-e-supercore/

And also I just came across this 5757 AGP brand turbo, at 65 lbs also, much less expensive kinda gets me excited about it: https://agpturbo.com/agp-turbo-z2-5757b-billet/
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Old 07-09-2019, 04:38 PM
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What exhaust manifold are you using? Would a t3 flange spacer work?
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Old 07-09-2019, 04:56 PM
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Originally Posted by Slowbalt2000 View Post
What exhaust manifold are you using? Would a t3 flange spacer work?
Possibly, the flange is slightly canted away from the engine too, I would need to measure hood clearances though. With the original setup when I got the car, the turbo outlet was basically touching the valve cover.

The picture is cut off but the hood was compressing that silicone elbow:

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Old 07-09-2019, 05:01 PM
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Is that a hahn mani? I have an ottp one that needs repaired but might fit better.
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Old 07-09-2019, 06:11 PM
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if you were to space the turbo up would that give you enough room on the bottom to reclock the compressor cover, put a tight radius 90 onto it so you dont have to run the charge pipe over the valve cover?
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Old 07-09-2019, 07:32 PM
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Originally Posted by Sharkey View Post
if you were to space the turbo up would that give you enough room on the bottom to reclock the compressor cover, put a tight radius 90 onto it so you dont have to run the charge pipe over the valve cover?
Going over the valve cover was the old way. The new way is clocked to go low into the air-water intercooler, there is also a support bar (which doubles as a "venom" brace suspension upgrade), you can see the welded 90 on the comp outlet:

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Old 07-09-2019, 07:35 PM
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Originally Posted by Slowbalt2000 View Post
Is that a hahn mani? I have an ottp one that needs repaired but might fit better.
It's a Performance Autowerks mani, an early 2.4 Solstice turbo kit. I've repaired some cracks a couple years ago, fun fact my cheap impatient ass used ACE hardware store stainless mechanics wire as filler and it has not cracked yet.
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Old 07-09-2019, 07:41 PM
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I feel like the spacer thing is too risky (we just don't know for sure), it could turn into a vortex of 'change this that that this and another thing' + $500 more in bits. I think I'm going to get that AGP 5757 for $750, looks like the safest best value path even though it might not be 100% optimized, it's still a step in the right direction.
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Old 07-10-2019, 07:26 AM
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Just go with a decent sized AR and it will be better than what you have now.
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