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Have you checked your #4 injector line hold down for tightness? When those guys get loose they can definitely cause a ticking noise. I don't think you can go wrong torquing the injector tubes, doesn't take that long and it's free. I suggest removing the entire rocker box for best access...

I'd check the TC bolts and make sure they aren't backing out.

My truck had bad blow by and it turned out to be a cracked ring on #1. Ran just fine and I must have put 20 or 30k miles on it running that way. I got really lucky it didn't fail or tear up the cylinder real bad:

Makes me think you have a wiring problem or an ECM malfunction. Even though you have a 2wd, the programming for 4wd is still in the ecm. Even on the 04-07 manual trucks there is still all the 48RE parameters in the flash file. If you have a wiring problem throwing off the reference voltage of...

If you read above there are several posts describing how my exhaust brake was installed and functions on my 2005 5.9 cummins 48RE auto. There is also a link that is dead now, new link is https://www.mm3tuning.com that talks about the tuning that makes this possible.

Yes I tow a 10,000 lb 5th wheel in the mountains as well. My TC does have a billet case though.

Also, slow uphill in 2nd... Shift to manual 2nd and get to about 25mph and the TC should lock, stock. Manual second is good up to about 40ish mph unless you have 4:11's.

I've been running a valve body with a shift kit on a torco (low cost) torque converter for over 3 years with plenty of towing. No signs of failing yet, but that's only my experience.

I would add, a box controller could inject a command to goose the throttle for relock like the 06-07 trucks do which would eliminate the need for locked downshifts like I'm using to hold lockup. So far with safe output shaft limits on when it will allow the downshift this hasn't been a problem...

On my 05 auto I have my pxrb pacbrake setup to run from the ecm via my own custom tuning. I do have a shift kit, but as I mentioned above even the 06-07 trucks (which can run a brake with stock tuning) don't ramp the ttva. I have confirmed this by looking at that parameter (ttva setting with...

Only time I had a hard time cold staring was when I had a cracked ring...

Lots of Allison voodoo out there. You can destroy an Allison transmission just like any other...

Sounds like you're talking about hydraulic tuning using valve body mods... For that you'd want to contact transgo, maybe they have some different spring options... On the other hand there is a good option for overall custom tuning on your 48RE:

I'd get an 07, 06, or 05 in that order. Reason being is if down the road you decide to put a tuner on it, that is the order of best computers these trucks had in case you decide to run a tuner. The 07 and 06 autos can also control an exhaust brake with ecm pins 39 (as cab switch) and 42 (brake...

Here you go for reference: Dodge Diesel 48RE Transmission Front Band Adjustment Video:

You'll probably slip your TC before damaging the od unit if you have a stock setup.

Nice glad you got it solved!

That breather box on top of the valve cover is supposed to separate oil from the vapors coming out of the crank case. In a perfect world vapors are sent on down the larger tube and exhausted under the engine. The oil that accumulates is then drained back down the smaller tube and returns to...

Are you getting any strange noises from the steering box? Another thing to check is to fire up the truck and have someone rock the steering wheel back and forth while you watch all the steering components to see if any of them are moving in a manner they shouldn't.

Should work fine. What are you using now to run that brake?