Mike: I'll attempt to answer your questions.
1) I believe the 5sd is the way to go. Better gear selection, and reliability and ruggedness, beats the auto. , without extensive mods. (147k mi. )
2) I DO NOT use any synthetic lube anyplace in the truck. 15w40 in the engine, (Valvoline All Fleet Plus) and the same in the Getrag gearbox.
3) The 16 cm hot end turbo housing is smaller internally (downsized from the 21cm2 stock unit) to spool up quicker, and provide higher boost. Cost is about 150. 00 from Ted J. , or Diesel Injection of Pittsburgh, etc.
The Transfer case / Gearbox filter is an Eaton part #K-1444 available from and good truck Transmission and parts supplier. 26. 00
4) Exhaust is a 3 1/2" dia. Banks freeflow stinger.
5) Oil filter Cummins Fleetguard Microglas, K&N air filter.
8) Occasionally pull 11000# equipment trailer.
9) With injection pump adjustments a guess at hp @240+, and torque @500. No dyno test, and don't care to, stock was 160 hp. , 400 ft/lbs. the truck rolls out quite smartly now, and I've got a few more tricks, tweaks and mods. to go. Take your time in your search, good luck, think again about the intercooler, it's a real asset. (oh yeah - 22 mpg. )
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92cum'ns 5spd 4wd all possible mods. to void warranty.
[This message has been edited by old school (edited 09-28-1999). ]