Engine/Transmission (1998.5 - 2002) 500 HP Recipe

[SPearson]

I am having to do alot of repairs and updates to my truck as a result of neglect by the previous owner. It is a 1999 3500 Dually 2WD with 4. 11 rear gears and an automatic (47RE). Rather than doing things twice, I was wondering if I could get your opinions on a good safe recipe to make 500 HP? What I am looking for is info on what I will have to replace (i. e. trans, turbo, injectors etc. ) and what I should add (i. e. Smarty, oring heads, studs, etc) to make this a RELIABLE easy to drive 500 HP truck. The more details you can give me the better. I can't afford to do the experimentation (parts breakage) myself so I hope you will share your experiences with me so I can do it right the first time. Like most folks, I have to really watch the budget so I will being doing as much of the work myself as possible. I am a helicopter mechanic so I'm not afraid to work on it. I just lack experience on the diesels. Thank you for your time and help!

Stuart

 

[Joe Mc]

My recipe was like this:



1- Gages (all are MUST HAVE) mine are all Westach on A-pillar: bottom: Combo Boost/EGT, middle: Trans Temp, top: Fuel Pressure.

2-Trans (weak link) I went DTT, there are others for sure but, DTT was my choice. Regardless of which company if you plan on making more than 350 HP/700 TQ the stock trans will die in short order.

3-4" Magnaflow exhaust w/through muffler, ATS 3-piece manifold (stock cracked) and SB air filter box & tube.



Now that the base items are in place; gages to show you what is/isn't going on, a trans that will put the power to the wheels and be reliable and more air in/more out - enter the power increase items.



4-Edge Comp (tap the VP).

5-HTT 64/14 turbo (set to open WG @ 45#).

6-F-1 Mach 5 (200HP) injectors.



No head studs, no drugs #2 fuel driven daily for last 50 w/this setup. Note HP/TQ numbers in signature.



Now this is using older technology, which there are newer items out there that may, or may not be better. For me the price was right on these items and have proven both effective and reliable, not to mention darn outright fun.



I'm sure more folks will chime in as time goes on.



Good luck w/you 99.

 

[fox]

I say, if you tow, and who doesn't with a dually, you need twin turbo's.

look at my profile, as I feel mine is about 450-475 hp.

i can tow for into illegal area's as far as weight goes. And it stay cool.

 

[DIESELWRKS]

you need to look at you fuel supply. FASS,Airdog, etc. make sure you have good fuel pressure. make sure you have a fuel pressure gauge. everyones stock head bolts are diff. also the amount of boost over time it can take. you may not need to right now but i would consider looking at studs or studs and o-rings in future. Welcome to the rest of your wallet "now entering the the diesel Bug" good luck let us know what your doing also where you live maybe there are some members near you.

 

[SPearson]

There aren't too many areas of the truck I DON'T have to work on/improve. LOL. Every part I work on I am trying to 'fix' so I won't have to do it again. The VP44 and lift pump were bad when I bought it so I put on a Thoroughbred Diesel VP44 that gives about 15% more power than stock (timing is cranked up) and installed a Airdog II 165 with a 1/2" line kit so I would not have to upgrade again as I upped the HP. I still have a few small things to do such as replace trans, upgrade to bigger brakes (4 wheel disk too), KDP fix, add guages, carrier bearing replacement, power steering pump screen cleaning/pressure adjustment, replace all battery cables, repair wiring due to pack rats eating the wires, install sport headlights, replace ball joints and stabilize the steering box, etc. etc. etc... . all the usual stuff in an effort to keep the Dodge part from falling off the Cummins truck! I'm on a budget so it will be a lengthy project and I drive it daily too. It's still fun to tinker with and learn about. I appreciate the info guys and I look forward to continuously improving this truck into something I can be proud of!

Stuart

 

[Joe Mc]

you need to look at you fuel supply. FASS,Airdog, etc. make sure you have good fuel pressure.

Stewart - DIESELWRKS is absolutely correct, I totally forgot to mention this critical part of the recipe. I went with a Walbro, rotary pump, 1/2" lines, Vulcan Draw Straw, 2 micron spin on fuel filter, and set my relief/return to tank regulator to deliver 22#. This 22# is delivered regardless of go pedal position = idle through WOT w/comp @ 5/5. So it does the trick.



I also got my replacement VP @ Thoroughbred when mine died last year? about 150k. I opted to go direct replacement SO pump without any tweaks.



Great outfit to deal with.

 

[jpickens]

My almost 500hp recipe...



Bad Stuff:

Leaking head gasket - both oil and antifreeze externally on front of head/block... 'fairly' slow leaks - has been this way for almost 2 yrs.

Nasty looking oil soaked BHAF with 48k miles on it - no 'cool air' separator between it and turbo.



Good Stuff:

185k miles on truck - original vp44 - injected/boxed from the 30k mile point... I have never abused any other vehicle like I have this truck (sled pulling/towing WAY heavy/two wheel peels almost daily)... I perform maintenance by the book and it has never let me down.



Run of the mill Stuff:

Edge drag comp

F1 EDM 3. 4 injectors

Super B turbo

BHAF filter in stock airbox location - heh

4" downpipe/exh. to 6" single stack

Higher flow fuel line banjo fittings & secondary frame mounted fuel pump



Results: (didn't know there was a dyno @ the fair - very last minute)

457rwhp 1025rwtq



Video:

YouTube - Dodge Diesel Dyno at Bloomsburg PA 4Wheel Jamboree

 

[SPearson]

Great info guys!

Great info guys! Thank you for posting. It doesn"t sound like it is too hard to get 500 hp out of the Cummins. It looks like I better go with twins due to occasional heavy tows (horse trailer) and also because of the heat out here in the desert. It's going to have to be a slow build for me due to the money and amount of repairs this truck needs, but I'll get there! One thing that does concern me is the emissions testing we have in Tucson. Any tips on getting 500 hp thru emissions? They do a quick physical inspection for things like modified exhaust and mods under the hood. How much trouble will I be in? Can I go with dual stock type exhausts with catalytic convertors and not choke my engine? Thanks again for the help guys!

Stuart