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post #1 of 56 (permalink) Old 04-21-2013, 01:57 AM Thread Starter
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PSI's Build & Picture Thread

PSI's Build Log & Picture Thread


Another busy winter has come to an end, and I'm finally ready to start building my truck up. The goal for the first stage of the truck is to get all of the supporting mods completed, followed by some EFILive tuning to waken it up. I have no intentions for a high-HP monster...yet.

I will be updating this thread with tons of pictures, and details of the build's progress. I'm mainly doing this for my own personal documentation, but also to gain insight from the more experienced. Don't hesitate to add your comments, I always like to hear what people have to say about my work.

The main modifications I'll be doing over the next couple months (not in any particular order):

-Southbend Dual-Disk 3600-GK
-FASS 150 w/ modified fuel canister
-EGT, FP, Rail, Boost Autometer Factory-Match Gauges
-2nd Gen. Manifold
-Borg Warner 63/68/14
-Custom Airbox w/ Amsoil Nanofiber
-Coolant Bypass
-EFILive

I'll be performing some minor cosmetic modifications as well, those will be added as they happen.

I looked high and low for a truck like this for a good part of a year. I wanted an '06 or '07 with the 5.9, reasonable KMs, no aftermarket, 4x4, G56 and a clean body. I finally found one in the next province over, and flew out and bought it after giving it a basic mechanical inspection. As soon as I got back into town with the truck, it was detailed and tinted. I picked up an MBRP straight-pipe kit from a friend, and threw that on just to tie me over.



The straight pipe got old pretty quick, so after some research, I picked up a 30" FTE Resonator. It made a world of difference. It's still loud, but there is absolutely no drone, and it is super quiet in the cab during normal/highway driving. I also threw an HID kit in, but those will soon be swapped out for a projector retrofit.

More to come!

-Kyle


07' 5.9 RAM3500 SRW(Build Thread/Pictures)
EFILive, Exergy 40%(124), 225lph CP3, 63/68/14, Hamilton 110#, Southbend DD, FASS150

Last edited by PSI; 06-05-2013 at 05:46 AM.
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post #2 of 56 (permalink) Old 04-21-2013, 02:24 AM Thread Starter
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I got sick of the black upper bumper cover, so I decided to get one paint matched. It definitely improved the looks of the truck, in my opinion.

The old:


Bumper after paint:


The new:


Much better!

07' 5.9 RAM3500 SRW(Build Thread/Pictures)
EFILive, Exergy 40%(124), 225lph CP3, 63/68/14, Hamilton 110#, Southbend DD, FASS150
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post #3 of 56 (permalink) Old 04-21-2013, 02:32 AM Thread Starter
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Clutch time! I decided to go with the Southbend 3600-GK, as I'm aiming for ~500hp. I do plan on going with an aftermarket turbo at some point, and possibly some nozzles. Doing that will easily bring me up into the ~600hp range, so this clutch is perfect.

From what I understand, Southbend has done quite a bit of work getting this to be a durable clutch, with stock-like engagement and pedal movement. I'm not really too concerned about the extra noise, simply because I know that the POS dual-mass flywheel is gone, and no longer a ticking time bomb ready to chop off my legs!

Anyhow, the installation begins:



I got the truck up as high as possible. Having access to a fully equipped HD shop is pretty nice! 12 ton jacks allowed me to lift the axles up 28" from the ground, giving me ~33" from the ground to the doors. It proved to be plenty of room to slide the transmission out while on top of my massive trans-jack.

After messing around with a seized bolt on the front driveshaft for an hour, I ended up welding a nut onto it and was able to pull it out. A trip to the stealership for a $13.00 bolt and we were back on our way. An hour wasted trying to get the bolt out with everything under the sun. Luckily, everything else went smoothly, and we were able to get the trans dropped with no hiccups.



After the trans was dropped, we realized the rear main had to be replaced. I was hoping that it was still intact, as I was hoping to skip the hassle of getting a new one in properly. At 3:15pm, I hauled over to the Cummins Dealership to pick up parts. Made it there at 3:50pm... I'm glad the staff there is very friendly and helpful, they had no problem staying an extra few minutes for me.



Pulled the old seal then got everything cleaned up in there, inspected the flywheel flange and found no damage. No need to sleeve! Woohoo! Drove in the new seal, then started on the flywheel.



It's nice to see a shiney, single piece flywheel in there! No more dual-mass BS!



I cleaned up the bellhousing and input shaft as best as I could. Holy crap was it dirty! Clutch dust, dirt, mud and PEBBLES! I was not pleased to find a bunch of pebbles in there, but I guess that's what happens when the roads are covered in salt/sand for 50% of the year. I used 4 bottles of brake cleaner and some elbow grease to get it that clean.

That's about as far as we got tonight, we'll (hopefully) be finishing up the rest tomorrow morning and have her rolling again.

-Kyle

07' 5.9 RAM3500 SRW(Build Thread/Pictures)
EFILive, Exergy 40%(124), 225lph CP3, 63/68/14, Hamilton 110#, Southbend DD, FASS150
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post #4 of 56 (permalink) Old 04-21-2013, 12:22 PM
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Lookin good. Keep up the good work.

Any reason you want to stay with the 351 since you are doing a 2nd gen manifold?

'05.5 6.7 Shotpeened NV5600 - 12.6 @ 111.6 - 994 HP & 1630 lbs/ft
150%'s, LBZ/Arson pumps, MHP +1mm, ZZFab, Wagler Rods, 69/73/1.0 & s482
1350 Frontshaft, TruTrac, 315's, 64" T-Bars,TGC 1/2"+, Carli BJ's, '08.5
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post #5 of 56 (permalink) Old 04-21-2013, 12:51 PM
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Nice truck. Can't wait to see how she turns out

2006 megacab 2500 Laramie leveled 35x12.50x20 toyo mt upgrade mopar steering box 8.5 steering upgrade, thuren track bar, protech cab guard & tool box, 4" straight pipe, k&n cai, silencer ring mia, efi.... someday
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post #6 of 56 (permalink) Old 04-21-2013, 01:56 PM Thread Starter
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Quote:
Originally Posted by Broaner View Post
Lookin good. Keep up the good work.

Any reason you want to stay with the 351 since you are doing a 2nd gen manifold?
I'd like to see how much power I can pull out of the HE351 and stock injector combination. Not only that, when I do decide to upgrade the turbo, the 2nd gen. configuration will make it easier to swap.

Clutch is in and torqued up, just gotta stab the transmission, bolt everything back up, and throw in the upgraded hydraulics. I'll post pics later.

-Kyle

07' 5.9 RAM3500 SRW(Build Thread/Pictures)
EFILive, Exergy 40%(124), 225lph CP3, 63/68/14, Hamilton 110#, Southbend DD, FASS150
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post #7 of 56 (permalink) Old 04-21-2013, 02:42 PM
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Looking good man!
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post #8 of 56 (permalink) Old 04-21-2013, 04:00 PM
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Alright, I get the logic. You gonna get a spring gate for it?

Also, I like the shop!

'05.5 6.7 Shotpeened NV5600 - 12.6 @ 111.6 - 994 HP & 1630 lbs/ft
150%'s, LBZ/Arson pumps, MHP +1mm, ZZFab, Wagler Rods, 69/73/1.0 & s482
1350 Frontshaft, TruTrac, 315's, 64" T-Bars,TGC 1/2"+, Carli BJ's, '08.5
Street Triple, 103#/Extreme Pushrods, 625's Broaner Gets Hooked
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post #9 of 56 (permalink) Old 04-21-2013, 10:38 PM
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Subscribed. Looks good


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'06 3500 G56, Dual pumps, 75% Injectors, 68/83/.90
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post #10 of 56 (permalink) Old 04-21-2013, 11:06 PM
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Nice work. Looking forward to the projector retrofit.

04.5 2500 2wd QCSB automagic. Carbon fiber wind sock.

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post #11 of 56 (permalink) Old 04-21-2013, 11:09 PM
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You had issue with the pinion bolts on the front driveshaft? I tried once for about 5 minutes. Now I normally leave those on and ziptie the shaft to the frame. When I have front driveshaft issues somebody else can deal with it.

'05.5 6.7 Shotpeened NV5600 - 12.6 @ 111.6 - 994 HP & 1630 lbs/ft
150%'s, LBZ/Arson pumps, MHP +1mm, ZZFab, Wagler Rods, 69/73/1.0 & s482
1350 Frontshaft, TruTrac, 315's, 64" T-Bars,TGC 1/2"+, Carli BJ's, '08.5
Street Triple, 103#/Extreme Pushrods, 625's Broaner Gets Hooked
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post #12 of 56 (permalink) Old 04-22-2013, 02:41 PM Thread Starter
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Out with the old:



In with the new:



Got to the shop pretty early sunday morning, finished cleaning the bellhousing and input shaft, greased it and put it together. Stabbed her in there, bolted up and started putting it all back together. I'm pretty sure with the equipment I have, and a knowledgeable friend, we could have the tranny out in under 2 hours.



So... I stripped one of those stupid external torx bolts holding the shifter on. I added a quart of ATF+4 before I put it on, but used only a small amount of gasket maker because I knew I'd have it off to switch to MTF. After going for a drive to warm the fluid up, I tried to take it off to start adding MTF and make a proper gasket, just to find it stripped. Guess that's what happens when you use a 12-point 10mm(?) socket instead of an actual external torx socket.

Luckily, there's a fill port located on the back, and I was able to pump though there.



I poured one quart MTF through the tranny in attempt to flush out the remaining ATF+4, but there was still quite a bit in there. So I filled er' up with 7 quarts, and I'll be draining 3.5 after a few hundred KM. If I can source anything less than a pale of Mobil Delvac 50, I'll be adding 3.5qts of that instead of Amsoil MTF.


edit: This did not hold, do not use zip ties. The boot popped off from the base and was leaking within a couple hundred miles. Use hose clamps.

My original orange shift boot had a very small hole that I probably could have repaired, but I decided to replace it anyways. Unfortunately, I forgot to get some pipe clamps, so I had to use some heavy duty zip ties. I'll be replacing them when I finish the fluids.

Quote:
Originally Posted by Broaner View Post
Alright, I get the logic. You gonna get a spring gate for it?

Also, I like the shop!
Thanks man, I'm lucky to have access to a fully equipped shop. Our new one is even bigger, and it has a pit!

I'm not sure if I'll be using a spring gate. I'll have to head over to the 2nd Gen. forums and see what kind of results they're having with it. I know they've been playing with our old HE351s for a while LOL.

Quote:
Originally Posted by Broaner View Post
You had issue with the pinion bolts on the front driveshaft? I tried once for about 5 minutes. Now I normally leave those on and ziptie the shaft to the frame. When I have front driveshaft issues somebody else can deal with it.
Yeah, just because they were torx headed. I sprayed them with penetrator the night before and that helped a little bit. Three of them came out easily, but one of them required enough force to start to strip the shallow torx hole.

Hmmm, zipping' it to the frame isn't a bad idea. I think I'll be doing that next time.

-Kyle

07' 5.9 RAM3500 SRW(Build Thread/Pictures)
EFILive, Exergy 40%(124), 225lph CP3, 63/68/14, Hamilton 110#, Southbend DD, FASS150

Last edited by PSI; 05-06-2013 at 04:11 AM.
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