My 2004 build-up

[MStaggs]

My truck is just for pleasure and towing my race car and trailer (10,000#).

It is a 2004 Calif spec 235 HP CTD.



I have been waiting a while before starting some "upgrading" and here are the results so far... ... .



The first thing I did was install some Isspro guages and a Mag Hytek trans pan. I like to see whats going on.



The next thing I did was remove the muffler (I left the cat on). What a difference! The thing is way more responsive and picked up an average of 1. 5 MPG. It also sounds like a real truck now.



Next I did the air box mod and installed an AFE filter. I also installed a Banks High Ram manifold.



The truck has been VERY good and fun to drive.



This week I installed a Banks Six Gun (I have had it for a while and never installed it). I have to say that I am VERY disapointed! It really does not feel hardly any more powerful at ANY of the settings (1 through 6 feels about the same). It was an easy install and there are no errors. It picked up exactly 1 pound of boost. It now makes 22 instead of 21. There is no smoke at all.

When I purchased the Six Gun, the guys at Banks said there would be a VERY noticable difference with my truck as its kind of "de-tuned" from the factory. Not so much.

 

[CFollett]

Same truck

Read my signature. I have the Smarty Jr. and it is great. I tow a 12500 lb 5ver. The only other thing I would like to do is a E-Brake. Great power and good mileage.

 

[MStaggs]

I will be wiring up the Speed Loader tomorrow.

I have an ATS exhaust manifold and new Wilson Intake to install later.

I am doing one thing at a time to better judge each components effectiveness.

Last will be a ball bearing turbo upgrade.

 

[Bob4x4]

The 235 hp trucks are very happy when running the Smarty,not so much with the Banks boxes... ... ... ... ... ... .

 

[jjdiesel]

left the cat on

If you "left the cat on" it must be a 04. 5. Just an FYI... . it may affect the approach one takes on upgrades.

 

[Joseph Donnelly]

jj, the 2003-4 Cal engines had cats, lower HP rating than federal.

 

[MStaggs]

The 235 hp trucks are very happy when running the Smarty,not so much with the Banks boxes... ... ... ... ... ... .

Hmmmm, apparantly they LIED to me at Banks. #@$%!

 

[jjdiesel]

jj, the 2003-4 Cal engines had cats, lower HP rating than federal.

Thanks Joe... . did not know that

 

[MStaggs]

Yeah mine is definately an 04 with a CAT. DAMN california smog Nazis!

 

[TCluff]

hook this guy up with a smarty and keep the rail pressure enhancement low

 

[MStaggs]

I put a single stage gated boost controller on it today and raised the boost up to 26 PSI.

THAT made a pretty good difference.

 

[Bob4x4]

The 325 version will hit mid 30's under load stock... ... ... .....

 

[MStaggs]

The 325 version will hit mid 30's under load stock... ... ... .....

I just donr know how hard I can safely push it.

 

[LWDUPPONG]

I was looking at the Banks package also. Sounds like what they told me word for word. I never bought it after talking to some of the guys on the board. I ain't got that kind of money to throw away. I was told I would get 25MPG too. I'm not that far from it now and don't have any mods at all.

 

[Turbo_Bob]

I just donr know how hard I can safely push it.

Low EGT's are one part of it, having the fuel system keep up with the increase boost is another part of it.



Threre are some minor differences between the CA 235 H/P engines, the 305 HO H/P engines and the 325 HO H/P engines.

I was looking through the TDR and could not find the artical about the differences of the engines, 235 / 305 / 325, so this is from memory.



305: has piston oil squirters, 23 PSI boost, I can get now 25 PSI fully loaded.



325: has the oil squirters, plus tri-metal rod bearings, stellite valve seats, re-designed radiator shroud, air deflector by air inlet to keep radiant heat from comming into the stock air box, 29 psi boost ?



I would take it easy for now until you gain more info, but 26 PSI sounds OK to me.

 

[MStaggs]

On a deisel, if the EGT's are high is it lean (like a Gasoline motor) or is it the opposite?

My EGT's have barely hit 1200 fully loaded and foot to the floor going up the Grapevine. Most of the time, they are 900 or below.

 

[Turbo_Bob]

On a deisel, if the EGT's are high is it lean (like a Gasoline motor) or is it the opposite?



My EGT's have barely hit 1200 fully loaded and foot to the floor going up the Grapevine. Most of the time, they are 900 or below.

I am not sure completly but on a diesel it could be both, "high EGT" because the (A/F is lean)



OR



(too much boost - high induction air inlet temps - low RPM).



I think 1,100 F before turbo the engine could run all day with no problems. At 1,200F to 1,300F is OK for brief towing spikes.



My numbers fully loaded going up 7% grades in 5th gear at 55 mph is around 1,100F, will go up to 1,200F at certin times depending on throttle / RPM and altitude.



My solo EGT is around 400 to 500, towing is around 900 and up.

 

[MStaggs]

I am not sure completly but on a diesel it could be both, "high EGT" because the (A/F is lean)



OR



(too much boost - high induction air inlet temps - low RPM).



I think 1,100 F before turbo the engine could run all day with no problems. At 1,200F to 1,300F is OK for brief towing spikes.



My numbers fully loaded going up 7% grades in 5th gear at 55 mph is around 1,100F, will go up to 1,200F at certin times depending on throttle / RPM and altitude.



My solo EGT is around 400 to 500, towing is around 900 and up.

Mine are the same

 

[Bob4x4]

Too much fuel(or not enough air) causes high egts in the diesel if you want to look at at in a simple manner.



Bob

 

[BMeier]

Yep, Bob is right your EGT's climb if you have a programmer pooring the fuel to the motor and the turbo can not get the burned fuel (exhaust) away. The factory turbo is said to be good up to 100 additional hp. I run the Banks 6 gun on my '03 305 hp and I have been very happy with the power, and very, very little smoke. Less smoke, makes for a cleaner internal engine compartment. I do oil sampling and at 88,000 miles the sample looks cleaner than the first two samples I took when the engine was new.