Upgrade my '96 3.54 manual shift 4x4

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Just got home with a '96 diesel and turned the '94 over to my son. Problem... ... . the '94 with the 230hp kit from TST will outrun my '96! What kits and upgrades do you all suggest? I have about $1000 to spend on such frivolity. Would like enough power to pull my 5th wheel @9000 lbs. without having to worry about hills and such. Would not like to have to go into major drivetrain upgrades.

Any suggestions?

Big John

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'94 2500 Diesel Reg. Cab
Auto 3. 54 4X4 TST 230hp
"If you can't Dodge it, Ram it!

 

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Big John,

Is the 96 the 215hp version? If so, go straight to the #11 TST plate. Call TST to make sure. It's 280/685 when put in the middle. 340hp on the ground when it's all the way forward with 215hp injectors, no CAT & 4" system. But, it's an EGT hog with a big load. #ad
#ad
You'll need an EGT guage.

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Money Sink - 96, 5 speed, Injectors, 280/685 & AFC housing slid.
4" CAT back & CATless, 4" chrome turn down straight out back.
ISSPRO Pillar, Delvac 1 & Amsiol, K&N, Monicas silencer ring removed, Exhaust brake, Mag-Hytec, 3:54, 235s.
HX35s days are numbered, HX40-16 is here.
Un-Bombed = Boring

 

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Big John, I agree with Forrest on the fuel-plate but with the addition of a few other items. I would strongly suggest, from experience, the 370 marine injectors, 280 fuel-plate, and 16cm housing, which are all well within your budget. I recently used the following set up for my last vacation in my 97, 3:54, 5sp, 4X4 SLT and was more than surprised at the pulling ability of this combo. With proper adjustment of the fuel-plate I was able to keep the EGTS below 1350 even on the very hardest pulls in the mountain passes and never ran out of power. I feel the 370 injectors are the key to this setup, as I have run the 280 plate with stock injectors and 300 marine injectors with the 16cm housing and was not impressed with the low end response and would not recommend the 16cm housing without the 370 injectors. The 370 injectors are the key to low end. I would not go to the 4" exhaust right away, mostly due to the cost in comparison to the return in horse power, you can always add it at a later time when funds are available. Just make sure that your cat is not plugged. DBR

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97 SLT 2500, 5sp, 3:54, 285/16, US Gear Under-drive, BD Hx40-16cm, BD 370 injectors, TST #10 plate, BD full 4" exhaust, Centerforce Clutch, and a few other items!

 

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I agree with DBR on the 370s. I just installed them this past Saturday and man the increase in low end power and in fact thru out the whole rpm range is just great. Huge increase. No more of that press the trottle, count to three and then go like hell. Even with my low stall converter, the truck goes like hell even from a standing start up a hill as you are depressing the trottle. The 370s made all the difference in initial take off. I had my AFC housing slid forward with the stock injectors, and have them now slid all the way back with the 370s to minimize smoke, but even so, the truck has immensely more power than before. I also do not have any of that 1100 rpm stumble some had mentioned. Joe D. had assured me my 180hp pump would work just fine with the 370s and he was right. TST plate, 370s and 16cm housing, and I would also include the AFC spring kit, if you do the labor yourself, should be just about a grand. You will probably have to beef up your clutch. (I know you did not want to do drivetrain mods. ) But you could just drive easy, heheheh. Impossible to do.


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1996 3500 Clubcab SLT, auto, 4. 10 limited-slip, TST #5, 370s, AFC spring kit, Psycotty, Dunrite converter, Trans-Go, Straight pipe, DiPricol EGT, boost & trans temp. gauges, 9 ft. aluminum flatbed and tool boxes with Venco dump. Custom front bumper, Hadley air horn.

 

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Thanks for the information. A few questions>>>>1. What does this #11 plate and 370 injectors do to your fuel consumption when not towing? I drive the truck daily on an 80 mile commute.
2. The 1350 EGT value mentioned is 150 degrees above what I consider safe for any duration. Have I bad information, or will this engine stand more temps than I am used to?

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'94 2500 Diesel Reg. Cab
Auto 3. 54 4X4 TST 230hp
"If you can't Dodge it, Ram it!
'96 2500 diesel clubcab 4x4 5speed

 

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Big John,
I'M running the TST#10 plate slid all the way forward with the AFC spring kit. I used the light spring and slid the housing all the way forward. Then installed the 16cm turbo housing, with a 4" exhaust from the turbo back. After that I put in 370HP injectors with the 3800 RPM governor spring kit. This lead to a McLeod dual disc clutch setup because the stock clutch had a burning desire to slip #ad
I am planning to install high flow delivery valves in the injector pump. I don't think you will have to worry about that pesky old 94 with this setup, as you will be able to spin your tires going down offramps in 4th gear #ad
#ad
Not that I'VE ever done something like that #ad


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96 2500 4x4 5spd 3. 54 grs,#10 TST plate,AFC spring kit,16 cm turbo,CUSTOM 4" exhaust, (turbo to tail),K&N RE-0880 filter,TST guages,370HP injectors,3800 rpm governor spring kit, Mcleod dual disc clutch(street),305/70r16 Goodyear Wrangler MT tires

 

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Big John,

Your mileage solo is still good. Under normal, non-heavy footed driving, the same. My commute mileage didn't change with the 280 plate in the max Bombed position. 17. 5 to 18. something mpg #ad
In fact, my hwy mileage is real good, I think. In 2 different terrain, 95% hwy runs, I'm getting 21mpg. #ad


I haven't changed the AFC spring yet. It's still almost the stock position. I dicked with it a little when I put in the 1st plate, the #8. I get smoke just during the very 1st part of acceleration, & under full throttle. That 280 plate, slid of course, has big time low end torque. Lots of fuel is happening there, which is why the smoke. The beauty of the plate is that it's there when you need it, but 'stock' feeling the rest of the time.

 

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I like Forrest am running the #11 plate all the way forward the AFC spring medium spring with the housing all the way forward. I drive 22 mile one way to work every day. My milage is better now than stock (as long as there no dorfs around) and my towing milage is 1 1/2 mile to the gallon better because I don't have to down shift. I suggest you put gauges on along with the #11 plate and lose the cat or at least it's insides.

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EAT'M UP
97 2500 Club 4X4 3. 54, Forrest Green/Driftwood, LSD 5 speed, & Psychotty Air System, TST #11 all the way forward, AFC spring kit, Geno's Exhaust Blanket, TST EGT gauge & 0-60 boost gauge in A Pillar, Cat-be-gone, 4" Dynomax Bullet muffler, Crome 4" turn down, AmsOil Through out, Geno's trans filter kit, AmsOil Bypass system, Lund Winter front, Leer Cab Level Shell Driftwood , 255/85R16 Big O ATs, Dyno'd 342 HP *NRA/USPSA member and proud of it*

 

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Big John, I do believe that 1350 is the maximum rated exhaust gas temp from Cummins (Piers or Joseph, feel free to interject). You can adjust your maximum EGT with your fuel-plate position. I set my plate position so that under the very hardest pulls when towing I will not go above the 1350 mark. This means I very seldom go above 1250 while pulling my trailer. I have to be into the throttle hard for an extended pull (long mountains grades) to get to the 1350 mark. I could easily push back the fuel plate and lower my maximum EGT, but that will also lower the power. Be sure that you install a set of gauges before doing any power modifications. I would suggest running the gauges for a while in stock configuration to establish a good set of base lines for comparison when you add the power.

 

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DBR and everyone. Thanks for the feedback. I do plan on installing gauges first. I run all three,EGT-Boost-Trans temp, in the '94. I will go with the EGT and Boost in the '96. I will increase air with a Pscotty airpack and replace the muffler and tailpipe with a 4" setup before I do anything to the engine.

Do any of you have a suggestion for the 4" exhaust?
I used Isspro gauges inthe '94 from Diesel Injection Services. Any suggestions on gauges?

On a separate note, when I got home with the truck, I checked the mileage. I bought it in San Antonio, when to the lease near Juno and returned home. My mileage was running 17 or so. My son said he was seeing black puffs when I would shift gears. I checked the air filter and found a NAPA filter in it. The filter looked like a regular OEM with an extra foam pad glued to it. The filter was VEERY RESTRICTIVE! Is this a normal NAPA filter. If so, do not use them. I changed the filter out with an OEM filter and my mileage when to 21 mpg!!


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'94 2500 Diesel Reg. Cab
Auto 3. 54 4X4 TST 230hp
"If you can't Dodge it, Ram it!
'96 2500 diesel clubcab 4x4 5speed