I need your opinions. I plan on buying a truck and I"m looking at an 04.0 and an 05. Both in excellent shape, similar money. Both have a manual transmission.

If it was your choice, which would you buy? And why? I've heard claims of better mileage with the 04's. Is that true? Thanks for your input.

 

Ive personally owned both and my '04 gets much better mileage than my '06 did.

 

I guess it would depend on if it's an 04 or 04.5...

 

His post said 04.0.....

I see most guys getting better mpg's in the 03/04's but some guys do well with 04.5+. You don't really have to have a HO 04.5+ to get big hp either. What a smarty alone can do on a HO you can do similar by stacking a programmer and tst or something on a 03/04. I had an 03 SO 5 speed that was regularly over 22-23 mpg.

 

'04.0 has a bonus, in my opinion, becuase there is no catalytic converter or electronic turbo wastegate.........

 

The 06 dually I have now surprised me in that it doesn't get much less than the 03 SRW I had previously... Maybe 1 mpg different. Both are stick shift 3.73 4x4's.

I'd say if they are both in similar condition, get whichever one you like better.

 

The '05 will have a cat, it also may have a plastic intercooler and some guys have complained about the Tow/Haul programming.

The '04 should get better mileage with no noticeable difference in power. I like the HO over the SO in the '04 year because of gallery cooled pistons, 11.5" rear axle and six speed manual tranny.

If you want to build it to the max for sled pulling the '05 might be a better choice because, I think, there are some cylinder head changes from '04.

A Smarty will be needed on either one for best mileage and performance.

 

From what I have found:

The 04.5 up have a third injection event, the 03-04 have 2 injection events.

Internal design:
1) Better pistons - I believe they they have a factory heat coating that 03-04 didn't.

2) Better valves - again,.. for heat protection.

(most of what was done was due to the 3rd injection event and the need to provide an engine that could handle more heat issues than preceeding models.

3) A bigger turbo.

HE351 turbo= 60mm; 03-04
HE341 turbo= 54mm; 04.5-On

4) An improved Intercooler (more cooling fins or deeper fins

5) 4" exhaust from the turbo to exhaust tip; 03-04 used a 4" to 3 1/2" exhaust elbow & 04.5 up used a 4" elbow

6) Improved injectors. Better spray pattern.

7) Not real sure on this one but I think the 04.5 has an improved head gasket over previous years.

8) Third injection event (more complete burn).

9) Improved exhaust manifold (thicker walls and flanges than previous).


04.5 and up the ecm is larger with more processing capability (3rd injection event again) and another reason they make bigger power more easily... also they have the oil cooling nozzles for the pistons. The 03-04 uses a "saddle" type system that is less effective.

04.5 and up have a better piston bowl design IMO that allows for more oxygen to get mixed with the fuel for a better burn. The 3rd injection event is a downfall......

 

I had a 04 555 engine and would never go back from my 06 both trucks were DRW. MPG is the same between the 2 (Hand calculated) power is way better in the 06 (Comparing stock and using the TST) The 04 never had any engine work neither has my 06 so reliability isn't a issue with either.
Another improvement way the fan design on the 04.5 and up

The only thing I didn't like better on the 06 is the gearing of the G56 vrs the NV5600.

The 05's had a plastic intercooler sides for about 1/2 a year and they were junk. Most of the one's that blew were replaced with all metal ones. The 05 can have either the NV5600 or G56.

 

Good point. I liked the NV5600 better, even though my 03 had one of the ones that didn't shift very well.

The G56 I have now shifts excellent, but it makes more gear noise, and 6th is considerably lower. As you noted, though, the higher hiway RPM doesn't seem to hurt MPG's as much as people think.

I also don't like the feel of the dual mass flywheel/clutch on the 06...

 

I got my 04 for many of these reasons, and wouldn't have it any other way!

 

The '05 advantage IMHO is the lift pump is already in the tank. The LP on the 04's WILL fail.
Mike
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But, this is a free dealer fix......