96' 2500 Ongoing Build Advice - Dodge Cummins Diesel Forum
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post #1 of 64 (permalink) Old 04-11-2019, 04:24 PM Thread Starter
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96' 2500 Ongoing Build Advice

1996 Dodge Ram 2500 Repairs & Modifications

Been reading this forum for many years and have plowed through all the stickies at one time or another although I can't guarantee a high retention rate on the info therein. Otherwise I probably would be able to answer this post myself.
I bought this truck new in 12/95 - One if the first made in Fenton(rip), MO. 193k. Have made repairs/upgrades as below. This is my DD and an ongoing hobby/project. I'd appreciate advice re engine modifications under the "To Do" heading below. Not looking for mega-power. +/- 400 and dependable is fine

DONE AS OF NOW:
Suspension:
Steering Linkage Conversion “Y to T” –
Moog Parts:
-Drag link: DS1459 $38.79
- Long tie rod (passenger side): DS1456
- Left tie rod end (driver side): ES3496
- Drag link upper end (at pitman arm): ES3497 (ES3527 for '00-'02)
- Small adjusting sleeve (drag link): ES2012S
- Large adjusting sleeve (long tie rod): ES3498S
Dodge Off Road (DOR) Track bar, steering stabilizer bracket
Bilstein Shocks
Ball Joints Raybestos Pro
Borgeson Box, Steering shaft, Power steering pump, Hose kit KLM Performance
Rock Solid Ram Truck - Steering Bushing
Front Hub/Wheel Bearings - Timken HA590020
U-joints – Dana Spicer
Control arm bushings - Energy Suspension
Steering Damper - Bilstein
Swaybar Links Genos Maxx
Sway Bar Bushings
Brakes:
-Power Slot Rotors – Front
-Hawk Pads
-Stainless Braided Brake Lines
-3500 Rear Wheel Cylinders
-Motul Brake Fluid
Eaton Transmission filter – Geno’s

ENGINE:
Westach Boost-Pyro
Adjust Valve Lash
New rocker box gaskets – Cummins Valve Cover Gasket 3930906 - O-ring PN#3910824 OEM Mopar
Adjust idle speed – 750 RPM in neutral with A/C on - w/ reference tach
Tork Tek adjustable overflow valve
P7100 Pump Stock Plate Full Forward
Cold Air Intake – 4”
Stock Downpipe – 4” cat delete – 4” straight through muffler/pipe
Gatorback serpentine belt
Dayco tensioner
Larry B Starter Diode
Oil: Schaeffer 7000 15W-40
Fleetguard Bypass Oil Filter
Flush cooling system. Restore Plus
Cooling System 24.3 quarts/6 7 gallons Fleetguard ES Compleat CC2825 150,000 miles
Clear A/C drain line – Extend drain hose to bottom of frame

Manual Transmission, NV4500HD
Standard Transmission & Gear Full Spline Mainshaft & NV4500 Rebuild Kit
18164 4500 5th Gear
27173 (4wd) 27176 (2wd) 4500 Updated Mainshaft Diesel
BK308UWSK T-4500UWS Bearing Kit
27133 4500 Updated Nut
8 pints - GM 12346190 or Mopar Manual Transmission Lubricant (PN 4637579) 5 quarts

South Bend Clutch: Product Specification: 13125-OK | 400hp 800tq
“The 13” Conversion kit has a larger disc and flywheel than stock. It is designed as a bolt-in application for the Getrag and NV4500 5-speed transmission. With horsepower options ranging from 400 to 550 there is sure to be an option that will fit your application.”
Kit Includes:
• Clutch Disc
• Pressure Plate
• Flywheel
• Throwout & Pilot Bearing
• Alignment Tool
• Pressure Plate & Flywheel Bolts

Transfer Case NV241HD ATF3 Redline C+ 4 qts
Differential, 4WD Dana 80 Rear..........10.1 pints 75W-90 Schaeffer #293
Differential, Dana 60 Front..........7.6 pints 75W-90 Schaeffer #293 - no more than Ό” below fill plug
9 quarts total for front and rear diffs.
Replace Rear Main Seal
Replace Pan Gasket
Replace Sound System
Kenwood KDC-X998 CD/Receiver
Kenwood XR400-4 75wx4 External Amp
Kenwood KSC-SW11 150w Subwoofer
Infinity Kappa 60.11 270w x2 Speakers - Front
Infinity Reference 5002ix 135w x2 Speakers - Rear

NorthStar AGM Batteries
Michelin MX2 Tires 265/75-16


To Do:
Engine Power Goal: +/- 400 HP, 0-3000 RPM Low End Increase, Dependability, Low/No Smoke.

TURBOS: ???
1. Stock Holset HX35 vs
2. Borg Warner AGPS300 Turbo 61-65-12WG vs
3. DAP Screaming Eagle SXE 62/68/12 /t3 gated hx40 – + 5x.012 inj. “best bang for buck” – J. Kidd
4. BD Exchange Modified Drop in Holset Turbo – Diesel Power Products vs:
5. High Tech Turbo HX35/40 Hybrid - Thoroughbred Diesel vs
6. K27 Turbo vs
7. Other??

TST #11 Plate – 280/680 TST Products vs #10 plate?
DVs??
16*??
Boost Elbow
AFC Spring Kit
Injectors – 5x.012 or ?? vs stock
Exhaust manifold Stainless Diesel
4” turbo-back exhaust Diamond Eye
Mishimoto hose set.
Core 4x4 Tier 4 Adjustable Control Arms –w/hardware – 0” lift vs
Dodge Offroad – Short Arm Non-adjustable Control Arms?
Oil Pressure Gauge – Isspro R17211 Lit
Auto Meter Single Gauge Pod
Beans Diesel Performance Multifunction Fuel Tank Sump
Battery Shut Off Switch?

Thanks for any/all info/advice.



Happy Trails
k9



'96 2500 4x4 5-spd, boost/pyro, kdp, stock plate fwd, Illflem style hole in the firewall CAI, 4" exhaust, Bilstein shocks, 195k mi. Y->T suspension, SB clutch, etc.
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post #2 of 64 (permalink) Old 04-11-2019, 07:33 PM
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An 11 plate is a low HP mod, my truck only made 297 hp at the wheels with one, stock injectors, stock turbo. The 10 is higher but I think a zero plate or a 100 will beat it. The stock plate full forward is a fuel waster, it's profile is not conducive to efficient adjustment. Bigger injectors and a better turbo will be required, but I can't offer any suggestions there.

97 3500, 2 WD, G56, slightly bombed, 1.3 million miles. Started the second million on 8/24/13
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post #3 of 64 (permalink) Old 04-11-2019, 09:00 PM
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I can attest that the #11 plate is great with a stock motor and the free adjustments (I got the plate from an ancient sage from Texas). There may be better plates out there, but I'm the hottest truck in town with it (though the population is less that 50 and don't think there is another truck around)....

98-4x4 5spd
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post #4 of 64 (permalink) Old 04-11-2019, 09:52 PM
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Wow, expenses that I never kept track of.
Great job.
Fuel plate and a K27 should do it unless you embrace the slush box, may the schwartz be with you.

'98 Ram 3500 12v 4x4, triple disc/47RE, 3.54s, 275 70 17's, TT OFV, gauges, 16*, K27, 055, 5 x 0.011, AFC live, 3 pcs manifold, MBRP, AFE
'18 Promaster 1500 HT
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post #5 of 64 (permalink) Old 04-14-2019, 12:40 PM Thread Starter
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Quote:
Originally Posted by RamCumminsRob View Post
Wow, expenses that I never kept track of.
Great job.
Fuel plate and a K27 should do it unless you embrace the slush box, may the schwartz be with you.
Rob-
How much HP/Tq do you estimate with your mods? Smoke much?

Thanks all for your replies.

'96 2500 4x4 5-spd, boost/pyro, kdp, stock plate fwd, Illflem style hole in the firewall CAI, 4" exhaust, Bilstein shocks, 195k mi. Y->T suspension, SB clutch, etc.
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post #6 of 64 (permalink) Old 04-14-2019, 07:27 PM
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Don't know my hp increase with the #10 plate, but I like it a lot more than the stock plate moved forward. I've got a super b turbo now, but recently read a thread that suggests a k27 over a super b for superior spool up. Can't comment on injectors. All you 12v guys talk about 5 hole injectors, where us p24v guys seem to have 7 hole injectors. I have stock, 7x.0095 and 7x.008. I like the 008s (aka 50hp) the best.
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post #7 of 64 (permalink) Old 04-15-2019, 05:43 PM
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Quote:
Originally Posted by k9american View Post
Rob-
How much HP/Tq do you estimate with your mods? Smoke much?

Thanks all for your replies.
The guy at Diesel Fuel Systems said 350 as is, flick the all in AFC switch and 450.
Probably should have done a dyno test but was happy as is.
If the pedal gets mashed, yes, but not too much, all AFC controlled by the way, so it is adjustable.

'98 Ram 3500 12v 4x4, triple disc/47RE, 3.54s, 275 70 17's, TT OFV, gauges, 16*, K27, 055, 5 x 0.011, AFC live, 3 pcs manifold, MBRP, AFE
'18 Promaster 1500 HT
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post #8 of 64 (permalink) Old 04-15-2019, 07:59 PM Thread Starter
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Turbos?

Compare & contrast: BW K27 vs BW AGP S300 SXE WG 61-65-12 WG.

'96 2500 4x4 5-spd, boost/pyro, kdp, stock plate fwd, Illflem style hole in the firewall CAI, 4" exhaust, Bilstein shocks, 195k mi. Y->T suspension, SB clutch, etc.
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post #9 of 64 (permalink) Old 04-17-2019, 12:26 PM
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Quote:
Originally Posted by k9american View Post
Compare & contrast: BW K27 vs BW AGP S300 SXE WG 61-65-12 WG.
wish i had the $$ to compare those myself. my bet it that either will get you where you want...K27 should be bolt in, but not sure about the 61/65/12...(it's really a 62 wheel though).

Good luck with the build.

BJ
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post #10 of 64 (permalink) Old 04-17-2019, 12:57 PM
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K27 is a small upgrade vs stock. Jump up to an s300 if you want more than 350HP. 57/65/12 billet with SXE wheel will do 450HP or to max out 400HP the s200sxe version we offer uses the same wheel and outflows the K27 even thoughthe k27 has a 60mm compressor (its lower profile so tip height is less).

K27 are also on back order for several weeks. We have 1-2 still on the shelf, but there will be a drought of them for quite a while.

SXE does not have a 61/65configuration unless its customized later. its a 61.44mm compressor and depending on the wheel and cover is going to do between 66-77lbs/minute
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post #11 of 64 (permalink) Old 04-17-2019, 08:31 PM
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What is the specs on the s200sxe. Sounds like the perfect hp turbo for compounds. Wouldn't be enough for drag or sled puller, but for towing or dd, it would be great.

What is the down side to instant spool and huge torque down low? Do you think drive line parts will suffer? Nv4500 input shafts or clutches?
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post #12 of 64 (permalink) Old 04-17-2019, 09:23 PM
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The lower the torque band the harder it is on driveline parts. Same is also true for engine components... Rods for example.

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91.0 D250 A727 w/ 216k on the clock. i/p replaced 20k ago, lift pump 2k, 1 turn fuel, 2 turns smoke, ground & polished AFC pin, timing bump, 366 spring 94 2500 4x4, 49k miles, Farrell Diesel rebuilt 215 pump, PDD 5x12 SAC, SXE 362, built 47RH
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