First real mpg test - Dodge Cummins Diesel Forum
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post #1 of 11 (permalink) Old 01-23-2020, 02:30 AM Thread Starter
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First real mpg test

Some of you know about my 12v Cummins powered Ford F-450, did the original conversion 7 years ago and swapped in the completely rebuilt 215 with upgrades 5 years ago.
I use this truck locally hauling hay and equipment between farms, it has only accumulated 30k miles in 8 years but hauls over 1000 rolls of hay per years plus moving skid loader and tractors, it's running average hauling, empty truck and trailer and occasionally just empty truck has been 10-12 mpg, not bad for traveling mostly rural secondary roads here in Ky.
Yesterday I had to go 280 miles into northeastern In to pick up a 2000 lb piece of equipment that would fit on the trucks bed, this was the first time the truck had been driven any distance empty on interstate highways so figured it would be a good time to do some testing on how the truck performed at speed and what mpg it could get.
First off let me say I was pleasantly surprised at how well the truck rode and drove, not as smooth has our 1/2 ton pickups we normally take on trips but the wife wasn't complaining about the ride so that's a + score anytime.
Most of the trip was at speeds ranging from 70-75 mph but I did run it up to 80 to get some gauge readings as well as a couple slower speed readings.

Truck is a 04 F-450 flatbed dually 4x4, 12v Cummins with 215 pump and inj, Colt Stage 3 cam and Borg S300 Super B 57mm turbo, ZF6 manual trans, 3.73 gears and 32" tires, terrain was mostly flat, truck weighs 9500 lbs, return trip weight was 11500 lbs.

60 mph at 1725 rpm, 3-4 psi boost, 500-600 egt
65 mph at 1850 rpm, 4-5 psi boost, 600-650 egt
70 mph at 2000 rpm, 5-6 psi boost, 650-700 egt
75 mph at 2150 rpm, 6-8 psi boost, 700-750 egt, the truck likes to cruise at 74 mph.
78 mph at 2225 rpm, 8-10 psi boost, 750-800 egt, I've always been told fuel mileage takes a noticeable drop above 10 psi boost.
80 mph at 2275 rpm, 10-12 psi boost, 850-900 egt, although the truck was cruising along fine the increased boost and egt's for only 2 mph increase told me we had passed the point were fuel milage was going to take a hit.
On the way back we stopped for fuel with 496 miles on the trip meter, 34 gallons later the tank was full which hand calculated to 14.6 mpg, I was hoping for 15 mpg and would have been tickled to see 16 mpg, had I stayed closer to 65-70 mph it may have gotten 15 or better, but that's not the way I drive and I wanted real numbers for my style driving.

I will be making some changes in the future but not sure when, while going over the truck greasing and checking fluids before the trip I noticed a good size oily mess at the left front side of the engine, after looking and wiping we found a crack in the bottom of the timing gear case between the block and power steering pump mount, the engine leaked a qrt of oil out in that 560 mile trip.
We'll be pulling the engine at a later date to repair of replace the gear case, at that time I'm going to swap in a stock cam in place of the Colt Stage 3 and probably replace the S300 with a K27, hoping these changes will help with a turbo lag issue I'm having below 1800 rpm.


Mine-04 F-450 SCFB 4X4 drw,5.9 12v 215 Ppump,ZF 6,KYclutch,KDP fixed,gauges,5x12's,15deg,3k GSK,60#,AFC Live, Super B single,Pusher intake,D celebrator brake,07 coil spring front conversion.
Her's-18 F-150 STX SC, 4x4, 5.0
Toy- 64 Fairlane, future 406FE, 3 Holley 2bbls, 4 spd

Last edited by Destroked 450; 01-23-2020 at 02:34 AM.
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post #2 of 11 (permalink) Old 01-23-2020, 06:06 AM
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Originally Posted by Destroked 450 View Post
I will be making some changes in the future but not sure when, while going over the truck greasing and checking fluids before the trip I noticed a good size oily mess at the left front side of the engine, after looking and wiping we found a crack in the bottom of the timing gear case between the block and power steering pump mount, the engine leaked a qrt of oil out in that 560 mile trip.
That's odd. What do you reckon caused that crack?
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post #3 of 11 (permalink) Old 01-23-2020, 09:17 AM
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EGTs and boost similar to my truck with stock turbo plus the free mods. My Mileage is a little better, but there are other factors. Wind is huge. I got 20 the other day but had a strong tailwind driving 75ish most of the way.

16 degrees timing on mine and 245/75/16 tires.

96 Ram 2500 4x4 automatic. Engine number: ??? Missing.
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post #4 of 11 (permalink) Old 01-23-2020, 12:27 PM Thread Starter
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That's odd. What do you reckon caused that crack?
I'm guessing it was vibration, the engine was a 2007 factory recon that came out of a airport shuttle bus, it did a lot of idling and they said us never driven over 15 mph, I bought it with a spun rod bearing and completely rebuilt it, the timing gear case is the updated version that prevents the KDP from falling out.
It does have a air compressor and MD truck power steering pump that adds more weight to the lower mounting flange than a dodge setup but lots of MD trucks running around with the same thing.



This is the second timing gear case I've seen that cracked in that area, other member had this happen a number of years ago, I don't think it was ever determined what caused it to crack.
Think I'll replace the case rather than try to repair it but thinking about welding a strip of flat bar along that area for reinforcement.
Plenty of time to think about it, probably won't tear into it till fall after haying is done.

Mine-04 F-450 SCFB 4X4 drw,5.9 12v 215 Ppump,ZF 6,KYclutch,KDP fixed,gauges,5x12's,15deg,3k GSK,60#,AFC Live, Super B single,Pusher intake,D celebrator brake,07 coil spring front conversion.
Her's-18 F-150 STX SC, 4x4, 5.0
Toy- 64 Fairlane, future 406FE, 3 Holley 2bbls, 4 spd
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post #5 of 11 (permalink) Old 01-23-2020, 01:07 PM Thread Starter
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Quote:
Originally Posted by ekvhekvh View Post
EGTs and boost similar to my truck with stock turbo plus the free mods. My Mileage is a little better, but there are other factors. Wind is huge. I got 20 the other day but had a strong tailwind driving 75ish most of the way.

16 degrees timing on mine and 245/75/16 tires.
That's pretty good and yes wind can have a big effect on fuel milage, took a oversize load to SLC years ago bucking 25-35 mph head winds across NE and WY, truck normally got 5-5.5 mpg loaded but on that part of the trip it was down to 2.8 mpg.
I know my trucks weight isn't good for fuel milage but locally it got 12-14 mpg with the worn out oil burning 160 engine, same fuel mods, same size inj, same turbo, same timing. The main difference between the engines is the 215 pump and Colt Stage 3 cam, it does have more power but many have argued that if your not using it you won't use any more fuel, so someone tell me where 2 mpg went to.

Mine-04 F-450 SCFB 4X4 drw,5.9 12v 215 Ppump,ZF 6,KYclutch,KDP fixed,gauges,5x12's,15deg,3k GSK,60#,AFC Live, Super B single,Pusher intake,D celebrator brake,07 coil spring front conversion.
Her's-18 F-150 STX SC, 4x4, 5.0
Toy- 64 Fairlane, future 406FE, 3 Holley 2bbls, 4 spd
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post #6 of 11 (permalink) Old 01-24-2020, 03:00 AM
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Quote:
Originally Posted by Destroked 450 View Post
I'm guessing it was vibration, the engine was a 2007 factory recon that came out of a airport shuttle bus, it did a lot of idling and they said us never driven over 15 mph, I bought it with a spun rod bearing and completely rebuilt it, the timing gear case is the updated version that prevents the KDP from falling out.
It does have a air compressor and MD truck power steering pump that adds more weight to the lower mounting flange than a dodge setup but lots of MD trucks running around with the same thing.



This is the second timing gear case I've seen that cracked in that area, other member had this happen a number of years ago, I don't think it was ever determined what caused it to crack.
Think I'll replace the case rather than try to repair it but thinking about welding a strip of flat bar along that area for reinforcement.
Plenty of time to think about it, probably won't tear into it till fall after haying is done.
I have that same PS pump on my truck. Eaton-Vickers V10NF attached to a gear drive mount. No air compressor. The pump itself is definitely heavier than the Saginaw used on a Dodge setup, but the Saginaw has an integrated reservior vs a remote reservoir on the Vickers, so Im guessing overall weight is probably a push. Hopefully I don't develop a crack there...
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post #7 of 11 (permalink) Old 01-24-2020, 11:41 AM Thread Starter
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Shouldn't be a issue, I had that setup on the 160 engine before replacing it, this one came with the compressor and I thought it would be handy to have onboard air on my farm work truck, and it is!

Mine-04 F-450 SCFB 4X4 drw,5.9 12v 215 Ppump,ZF 6,KYclutch,KDP fixed,gauges,5x12's,15deg,3k GSK,60#,AFC Live, Super B single,Pusher intake,D celebrator brake,07 coil spring front conversion.
Her's-18 F-150 STX SC, 4x4, 5.0
Toy- 64 Fairlane, future 406FE, 3 Holley 2bbls, 4 spd
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post #8 of 11 (permalink) Old 01-24-2020, 08:10 PM
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Definitely add something, that is a lot of weight swinging off.

An fl80 with an 8.3isc i used to drive had a braket that supported the big compressor and that engjne is quite a bit bigger.

Daily driver/ workhorse: 1994 2500SLT 4x4 Auto. Hewitt EGT, Boost, Trans gauges, Under hood Mech FP gauge, Trident fuel lines, Tork Tek OFV, Mag-Hytec DD Transmission Pan, Ford manual hub conversion, Diamond eye 4" turbo back, 37337 Upgrade. 260K

98 2500slt 4x4 ECLB moldy G56, south bend clutch 3rd gen trac bar , boxed control arms, billet tappet cover w/ dual breathers trident fuel lines, Tork Tek OFV, 4' stainless side dump with muffler 240k
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post #9 of 11 (permalink) Old 01-24-2020, 08:27 PM Thread Starter
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Cousin has a FL60 with 5.9 and air brakes, I'll look at his for a bracket, mine was a complete engine but didn't have a bracket, being a recon engine it could have been left off during the swap.
I have a F-800 with the 8.3 and larger compressor.

Mine-04 F-450 SCFB 4X4 drw,5.9 12v 215 Ppump,ZF 6,KYclutch,KDP fixed,gauges,5x12's,15deg,3k GSK,60#,AFC Live, Super B single,Pusher intake,D celebrator brake,07 coil spring front conversion.
Her's-18 F-150 STX SC, 4x4, 5.0
Toy- 64 Fairlane, future 406FE, 3 Holley 2bbls, 4 spd
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post #10 of 11 (permalink) Old 01-24-2020, 09:21 PM
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Quote:
Originally Posted by Destroked 450 View Post
Cousin has a FL60 with 5.9 and air brakes, I'll look at his for a bracket, mine was a complete engine but didn't have a bracket, being a recon engine it could have been left off during the swap.
I have a F-800 with the 8.3 and larger compressor.
I mean look a the pump its about the same size and it has brackets.

Even the tiny vacuum pump and factory ps pump have brackets to support the weight.

Daily driver/ workhorse: 1994 2500SLT 4x4 Auto. Hewitt EGT, Boost, Trans gauges, Under hood Mech FP gauge, Trident fuel lines, Tork Tek OFV, Mag-Hytec DD Transmission Pan, Ford manual hub conversion, Diamond eye 4" turbo back, 37337 Upgrade. 260K

98 2500slt 4x4 ECLB moldy G56, south bend clutch 3rd gen trac bar , boxed control arms, billet tappet cover w/ dual breathers trident fuel lines, Tork Tek OFV, 4' stainless side dump with muffler 240k
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post #11 of 11 (permalink) Old 01-24-2020, 10:43 PM Thread Starter
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Those where gone off of the 160 engine when I got it, didn't know they where supported.

Mine-04 F-450 SCFB 4X4 drw,5.9 12v 215 Ppump,ZF 6,KYclutch,KDP fixed,gauges,5x12's,15deg,3k GSK,60#,AFC Live, Super B single,Pusher intake,D celebrator brake,07 coil spring front conversion.
Her's-18 F-150 STX SC, 4x4, 5.0
Toy- 64 Fairlane, future 406FE, 3 Holley 2bbls, 4 spd
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