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 Genos
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