I am totally new at this and I mean NEW!!! I own a '96 Ram 3500 Dually w/4:10 rear, auto, Cummins 5.9L, and all is stock. I am the original owner and decided last year to restore this truck back to showroom. All the interior, suspension, Bilstiens, steering dampers, airbags, headlights, taillights etc., you get the picture, has been replaced or repaired. NOW comes the hitch!!!! I have always towed my boat, 6K lbs., or my 5th wheel, 10K lbs., but only for short trips. Now I am in a situation where I am going to have to relocate some 1800 miles from where I am and need to get more power out of this truck. I will be towing a 7.5K 40' gooseneck enclosed race car hauler with all my stuff in it. Probably max out at 16K per trip. What can I do, injector wise, etc. to boost the H.P. and give her some extra breathing room. Any and All suggestions are welcome. Bear in mind this is the older totally mechanical engine, no chips etc. to install. Thank You in advance for your help!!!!!!!!!

 

Two primary things you will need BEFORE you add in the power will be gauges and improvements (upgrades if you have not already) to that auto tranny if you do NOT want to ruin it.

Then add in a #10 fuel plate with a 3k governor spring kit and bump the timing up to 15.5 - 16 and you will be ready to go.

 

First off welcome to the site! If you have some time to use the search function here and on the 12V engine/drivetrain forums you will find tons on info on mild performance increases. I'm not sure how many miles are on your transmission, sounds like you take care of your truck, but either way that will be the limiting factor for power without at the very least a shift kit/new valve body, and preferably a new torque converter. With the mechanical injection pump (p7100) it is very easy to basically double your stock hp/tq, stock auto will not last very long using that power.

Set of gauges is first, so you can keep an eye on everything to make sure you aren't overfueling/not getting enough air at any point. Pyrometer for exhaust gas temp, boost pressure gauge, and trans temp would be a good starting point. Then you can add fuel with the fuel plate, searching will give you info on that, seems like a #10 plate is good for towing.

A 3k rpm governer kit is easy to install and gives you full power to around 3k rpm, instead of the stock setting of reducing power around 22-2500 rpm, this will give you a much broader power band and makes towing a lot easier.

With just those upgrades you can add around 50-70 hp and at least 200 lb-ft of torque, which will make towing that trailer much easier. Like I said earlier, you might get away with leaving the trans as is for some time, but it will eventually start to slip under load, so increasing holding pressures with either a shift kit or new performance valve body will at least help hold the stock parts together.

Have fun, start digging into the search function!

 

Thanks alot for the quick info. Setting aside the tranny issue, what should I be looking at $$$ for the gauges, plate etc. and is this something I can do myself. I am mechanically savvy but with bad arthritis in my hands things can get a little frustrating. Thanks again
Mike

 

You should be able to handle the Fuel plate install no problem the governor spring kit is a little harder but in the same area as the plate.
Gauges should also be very doable for you.

Costs - Fuel plate with boost elbow $30-50 on fleabay
Governor spring kit $100-200
Gauges $175-400 depending on what you get along with a mount.

Lots of good info on this site for the plate and spring installs, just read up on it and get familiar before you go at it and take your time, be clean and precise and it will come out right.

 

OK...I have done my homework now and man what an interesting process. I have purchased the following:
3K gsk-boost elbow-#10 fuel plate-3 unit gauge kit w/A pillar pod.
Now for the tranny. Would you recommend a unit from DTT built to spec of power output or purchase the necessary kit, VB, TC, etc. and have someone rebuild my existing unit??? Also what are your thoughts on a 4" exhaust, muffler or straight thru? I am looking for a fuel filter relocation kit, Prime Loc no longer does these, any leads?
You guys have been great and I really appreciate all the attention and insite I have been given.
Mike

 

I personally would go one-stop-shopping for your tranny of choice. The companies that specialize in diesel trannys really do have it down to a science. Specify your intended HP output and intended use and they build a tranny to that spec. Spend the coin up front on a good tranny to get your power mods to the tires the first time. As for exhaust, the factory stuff will easily support 300hp and more, but 4'' does sound cool. No real performance gain to be had there, imo. Others will differ on that opinion I'm sure. Towing heavy without a muffler can get annoying, depending on your idea of loud. I have a 51'' Donaldson semi muffler that I would band clamp in when towing heavy for any distance. Replace with a piece of straight pipe for daily driving to hear that sweet Cummins music! Aftermarket filters are cool, but over 600HP has been had time and time again on the factory lift pump/filter setup on trucks like yours. A fuel pressure check will let you know where you're at, then you can go from there.
hope this helps some...
greg

 

Yes, if you haven't already done so get yourself a fuel pressure gauge. You need to keep a steady stream going to the injection pump. Something as stupid as a $30 overflow valve (basically a fuel pressure regulator) or a $20 rubber hose can damage your expensive injection pump. I would say have one of the big companies build you a trans and be done with it. As others have said, no need for a filter relocation, just replace the stock lines with the correct marine grabe diesel rated rubber hose. I would go with a 4" exhaust with a muffler but I would avoid the bullet types that look like an overgrown version of the old cherry bombs. My 4" was like that and it was noisier/droned more than my current 5" system. My cousin has a nice 4" stainless set up on his that was priced comparably to most aluminized steel systems and is relatively quiet compared to the aftermarket systems I've heard. If you want I can ask him what kind it is, I'm probably going that route next time too. What gauges did you end up getting?

 

I purchased the Boost, EGT, and Trans temp gauges. Brand is GloShift, comes with necessary accessaries for install. Any tips on a tranny builder. I have looked at DTT but that is about it. Recommendations????
Thanks Mike

 

Gauges then this> http://dieseldatabase.com/read.php?id=58

 

OK...One more thing. This is just from an economics stand point. I have contacted DTT and have received a quote with specs based on the weight and use criteria stated. Here is the question. The core charge is $800 and return shipping is about $250 so my net from the old tranny is $550. There is NOTHING wrong with this trans. 100K miles and just serviced. Don't you think I just keep it and sell it for alot more than that? Or keep it just in case?? What do you think it is worth??
Once again, Much Thanks
Mike
ps-my wife is going to have a cow but it is cheaper to pay now than in the middle of the west texas desert.

 

Think you might find a better deal here> http://www.goerend.com/

 

I would run gauges, 4k gov springs, pull the plate, close the wastegate. Let her buck. I would monitor fuel pressure. Could run a rack plug, but that minor stuff. AFC foot modification, but that more fueling if you done everything. Delivery valves and injectors.

Run a high quality lift pump, solves lots of lack of fueling issues.

 

The 12 valve comes with a high quality, very reliable mechanical lift pump.

 

Once again, Thanks for all the help. I would still be fumbling in the dark if it was not for the help all of you have submitted. I pulled the trigger on a tranny Wednesday. I went with DTT and didn't scrimp on this item. Went with the following: Billett input shaft, triple disc torque converter, billett drum and billett flexplate, custom valve body with billett band anchors, 2nd gear billett servo and accumulator, upgraded 3rd gear clutch, and the mag DD pan which holds an extra 4.5 quarts of Tequila. This may have been a little overkill but as they say "Pay me now, or, pay me later" and going along those wide open stretches of asphalt on either I-40 or I-20 a towing bill could be in the thousands plus downtime. Not that something couldn't still happen but I wanted to narrow the possibilities of "Murphy" making a visit. I will now commence installing all of the parts I have acquired over the past two weeks.
Thaanks Mike