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TECH SPECIALIST
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Discussion Starter #1
Note on photobucket... no more image hosting so links to pics will be broken.

http://www.cumminsforum.com/forum/3rd-gen-non-powertrain/2286633-no-more-image-hosting.html#post26602217



grouping these into one post and linking into my sig so they are easier to find... should help anyone looking for mpg input.

mpg & mods
http://www.cumminsforum.com/forum/3rd-gen-non-powertrain/1164202-mpg-mods-info-my-experience.html#post13025722

cold weather & mpg
http://www.cumminsforum.com/forum/3rd-gen-powertrain/1368449-cold-weather-mpg-thread.html

Mpg quest
http://www.cumminsforum.com/forum/3rd-gen-non-powertrain/548763-mpg-quest.html#post5686344

2nd air dam
http://www.cumminsforum.com/forum/3rd-gen-non-powertrain/557070-diy-3rd-gen-ram-secondary-air-dam.html

Airbox mod test
http://www.cumminsforum.com/forum/3rd-gen-powertrain/1993130-airbox-mpg-test-experiment.html

Cheap airbox mod
http://www.cumminsforum.com/forum/3rd-gen-performance-parts-discussion/1873074-cheap-airbox-mods.html

Fuel cooler
http://www.cumminsforum.com/forum/3rd-gen-powertrain/1722746-fuel-cooler-install.html

t-stat
http://www.cumminsforum.com/forum/3rd-gen-powertrain/2040306-190-f-stat-vs-200-f-stat-mpg.html

newbies guide to your new truck
http://www.cumminsforum.com/forum/3rd-gen-powertrain/1909713-newbies-guide-your-new-you-truck.html

Why you dont want a k&n filter
http://www.cumminsforum.com/forum/3rd-gen-powertrain/2040602-k-n-filter-pic.html

Coolant hose p/n thread
http://www.cumminsforum.com/forum/3rd-gen-non-powertrain/1896370-need-part-hose-behind-exhuast-manifold.html

HPT mpg thread
http://www.cumminsforum.com/forum/3rd-gen-powertrain/2075258-hpt-mpg-thread.html

Gear Ratio Calculator
Gear Ratio Calculator

Acronyms
ABT = Airbox intake temperature (Temp inside the airbox, close to ambient)
IAT = Intake air temperature (at the manifold)
CT = Coolant Temperature
CAC = Charge Air Cooler aka intercooler
OAT = Outside Ambient Temperature
2SO = 2 stroke oil (TC-W3, supertech at walmart)
ATF = Auto trans fluid (Dex/Merc, non-synthetic, supertech at walmart)

FSMs

08
https://www.dropbox.com/s/6zpj3e15mh2e8h6/2008 DR FSM.pdf?dl=0


06
https://www.dropbox.com/s/rwus86v9aw946ue/2006 Dodge Service Manual .pdf?dl=0


05
https://www.dropbox.com/s/0rahzhgrioyctno/2005-DR-SM1.pdf?dl=0


04

https://www.dropbox.com/s/ieajb1t38wi055w/04DRM.pdf?dl=0


03
https://www.dropbox.com/s/ojzvdn3wcswhi3v/2003 DR FSM.pdf?dl=0

Atf oil info
Petroleum Quality Intitute of America

exhaust manifold blanket
5.9 6.7 CR Cummins Common Rail Manifold Blanket fits stock and afterma ? Turbo Performance Products

Stumble issue related to trans harness
http://www.cumminsforum.com/forum/3rd-gen-powertrain/1996466-output-sensor-issue-2.html

Coolant temp chart post
http://www.cumminsforum.com/forum/3rd-gen-non-powertrain/2115561-cold-start-up-2.html#post24492361

Fuel rail pressure ramp up graph
http://www.cumminsforum.com/forum/3rd-gen-powertrain/2124034-rail-pressure-ramp-up.html


front steering post
http://www.cumminsforum.com/forum/3rd-gen-non-powertrain/1973297-finishing-front-end-upgrades-still-floating-down-road-2.html#post22910185

Htt airflow pkg writeup
High Tech Turbos Airflow For Tow Cummins Package

tires...270k @ .16/32"

http://www.cumminsforum.com/forum/3rd-gen-performance-parts-discussion/2104481-altitude-tuning-question.html

Plastic sheets for CAC
http://www.tapplastics.com/product/plastics/plastic_sheets_rolls/hdpe_m_m_opaque/258

Shop that can fix ECM at a reasonable price... credit Chevokeeman... thanks!
https://www.autocomputerexchange.com/


Fuel lubricity study
Lubricity Additive Study Results - Diesel Place : Chevrolet and GMC Diesel Truck Forums

http://www.cumminsforum.com/forum/3rd-gen-powertrain/2201114-injector-tips-atf.html

Carli Ball joint servicing info
http://www.cumminsforum.com/forum/3rd-gen-non-powertrain/2279138-psa-carli-ball-joint-servicing.html

external voltage regulator
https://store.alternatorparts.com/hd-external-voltage-regulator-conversion-field-replacement-kit.aspx

Fan clutch conversion
http://www.cumminsforum.com/forum/3rd-gen-powertrain/2334673-fan-clutch-conversion-parts.html

Another option
I gave up on my volvo fans. I am towing too heavy now.
I also gave up on the stock 3rd gen electro-hydraulic fan clutch after cutting another set of wires.

Instead I have installed the following parts, ordered from RockAuto:
1999 DODGE RAM 2500 PICKUP 8.0L V10
HAYDEN 2791 Radiator Fan Clutch $ 38.79 $ 0.00
2001 FORD F-250 SUPER DUTY 7.3L V8 DIESEL Turbocharged
MOTORCRAFT YA225 Radiator Fan Blade $ 71.79

Total delivered to my door was $115.

1999 V10 severe duty fan clutch had the correct thread pitch, the 7.3 fan bolted right up with some metric hardware, and the fan leaves a ~1" gap to the shroud.
Havent had any issues at all, but its not summer at 24000lbs gross yet.

Volvo fan conversion with results
http://www.cumminsforum.com/forum/3rd-gen-performance-parts-discussion/1857074-electric-fans-flex-lite-kit-doesnt-cut-need-ideas.html#post21390418

Dodge fan clutch part # 52027885 can be bought under $80. Overall height is 3 5/8" from front of fan clutch to the Cummins hub. The fan clutch sticks out further than the fan blade. Bolt up a 7.3 fan blade and you're good to go!
Dorman 620-883 Radiator Fan Assembly

Volvo fan relay from '97 Volvo 850, or search rockauto.com Volvo 2003 C70 (and older) electrical Switch & relay -> radiator fan relay. This relay used in multiple cars up to 2003

http://www.cumminsforum.com/forum/3rd-gen-powertrain/1652833-diy-electric-fans-research-discussion.html#post18938121


http://www.cumminsforum.com/forum/3rd-gen-powertrain/1652833-diy-electric-fans-research-discussion.html#post18938121

ignition switch swap
http://www.cumminsforum.com/forum/3rd-gen-non-powertrain/2377666-05-ignition-switch-sticking-intermittently.html#post27808642

Water pump info
https://www.turbodieselregister.com/threads/240248-Water-pump-upgrade

Cardone is an aftermarket water pump manufacturer and they build products superior to Gates and OEM (for a little more money); Cardone pumps use roller bearings. Cardone makes only two pumps for all these model year trucks. Model 5531411 is specified for model years 89 to 07 5. 9 liter and model 5531412 for the 6. 7 liter 08 and up.

The 5531411 uses a five blade stamped impeller. The 5531412 uses a 7 blade cast iron machined impeller. The Gates pumps use five blade stamped impellers for both of the 5. 9 engine pumps and a composite (plastic) 7 blade impeller for the 6. 7 liter pump.
Mixed reviews on the cardone parts... buyer should research. I personally had a gates last just 2 years, went back to oem cummins.
 
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Great Steve... you make this look sooooo easy! grrrr! 21mpg!..... I'm trying to clear 15! :)
I do tow heavy and drive back roads mostly. I dont have a mpg reading on my Touch, would engine load % give me an idea of mpg?
Example= 4th at 40 mph =20%~ eng load /VS/ 3rd @ 40mph= 10%~ eng load
 

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TECH SPECIALIST
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11,029 Posts
Discussion Starter #3
yeah it may look easy but not so much. LOTS of testing has gone into those threads. The only two I never was able to say yes or no on were the 2nd air dam and the tailgate spoiler. I suspect the tailgate spoiler only works on lowered, normal height 2wd trucks. I know the 2nd air dam actually had an effect once I dropped down from the 3" springs to the 2" springs. I could actually hear it rattling. Plus in MN the fluid film was blown off on the bottom half of the front diff. I suspect that one would be better if it were a 6" version that dropped down another inch vs the 5 I worked with. Leveraged the idea from Ford's F150's which also inspired the tailgate spoiler purchase. Saw a video a while back of the F150s aero developments and one of the featured area's was the 3rd brake light & the integrated tailgate spoiler. They did not mention how much of a benefit it was but it was a contributor to their numbers.

I am planning to drop back in a 190* t-stat in prep for the efan install. I believe I will have a mpg drop with it. I want to have it there to give an extra 10*f of head room with the assumption that the fans dont fit (too thick) and I have to run around for a weekend fixing it. Heading back to Cali over Memorial day weekend and will be there the whole week, maybe thats a good time to do the install since I'll have my tools to fix whatever problem I encounter.


RE: calc load question... nope that example you gave wont work, you'd be in a higher rpm range which would be potentially dumping more fuel. Depends on the tune. ONe of the biggest things that can be done for improving mpg with the tune is to drop rail pressure in the cruise zones. 3 injection events, lower pressure across all events will drop fuel useage.
 

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TECH SPECIALIST
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Discussion Starter #6
Agreed... I only have experience with one injector purchase though, bought new...

that thread should come from someone who has been around that block and has more knowledge from first hand experiences...
 

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TECH SPECIALIST
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Discussion Starter #7
Mpg feedback... Just drove from seattle to sac, 63-68 mph most of the way, 4 or 5 summit crossings, 21.8 mpg. Had an issue on one of the grades where traffic got hosed real quick with a semi changing lanes to keep his momentum up... had to downshift and bokst did not come back up for some reason resulting in a nasty cloud of black smoke. Decided to open up the vent on the bottom of the airbox for the next two summits (4000+ and 3500+ ft). At the higher engine speeds 2000-2300 it felt stronger which gave me a reason to have that electric cutout on ths bottom of the box...

Open it up when approaching a steeper grade and keep it closed on the flats. Open it should help a tad bit with egts and i think make pulling the grade easier. I say this cause i believe the torque curve moves a bit higher in the rpm range with more air into the box. Would love to prove that some day along with the fuel cooler...
 

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Discussion Starter #9

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Man, wish I could do more highway driving to boost up my mileage average. I'm stuck in mostly around town driving the majority of the time which drops my average. Guess I can't complain too much, mine is 18.26mpg for the 10 year average. Lost the data prior to the 10 years.
 

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TECH SPECIALIST
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Discussion Starter #11
Great information. Do you have photos of your air box cut out?

Hey your in the PNW...(?) if your looking to do airbox mods i could be talked into loaning you mine for you to play with before cutting your box. From my experience playing with it... I would recommend doing an electric exhaust cutout on the bottom... that would give the best of both worlds for mpg (closed) and open for towing or high airflow demands. The vent that I have by itself if opened full works ok with the tune I have for the fully closed box, going with the additional openings however then it starts lacking. The 4" e-cutout would have slightly more flow (iirc) than just that butterfly vent I have on. This e-cutout is in my trucks future for sure.

Man, wish I could do more highway driving to boost up my mileage average. I'm stuck in mostly around town driving the majority of the time which drops my average. Guess I can't complain too much, mine is 18.26mpg for the 10 year average. Lost the data prior to the 10 years.
18's is pretty damn good over 10 years. I cant say I have that, if I were to guess its probably in the mid 16's for me over 10 years. The last 3 though I'd say its closer to 19. So far this year its upper 19's. Last month it was over 20.
 

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I just went with Anarchy EFI from a Smarty. Much smoother power and super clean exhaust. I seem to be getting hopefully 1 mpg more. I'll hand calculate soon.
I'm running Toyo AT2's. I wish Toyo'd offer a 295-75-17. A dab wider and approx 35" tall.
 

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This should be sticky! I'm just saying!
 

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TECH SPECIALIST
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Discussion Starter #14
I just went with Anarchy EFI from a Smarty. Much smoother power and super clean exhaust. I seem to be getting hopefully 1 mpg more. I'll hand calculate soon.
I'm running Toyo AT2's. I wish Toyo'd offer a 295-75-17. A dab wider and approx 35" tall.
What are you getting now? Iirc the camper is always on right?
 

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What are you getting now? Iirc the camper is always on right?
I'll check pretty soon. Last tank had $20.00 worth of HPR Propel bio in it.
Yeah,camper's on 24/7. On the few occasions I take it off the truck loves it. It is about 1800# wet and still pushes a bunch of air.
 

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TECH SPECIALIST
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Discussion Starter #16

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TTT for the new members.
 
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