Dr Evil

I have an 02 5.9 5 speed truck.

Here is what I would like to do.

I would like to put in a 6 speed trans. (swap out the 5 speed)

I would like to put in 50 to 100hp injectors.

Better intake

larger turbo.

Possibly a better intercooler.

FASS Lift Pump

Possibly a modified vp44 Injector pump.

The use for the truck would be a daily driver

and to tow gvw 19,000lbs.


I would like to get about 24mpg. empty of course

Is this all possible?? If so, can someone give me suggestions as to Upgrade

kits, turbos/injector combinations??

How is Banks. I hear they are pretty conservative.

I think I want hp to be aroud 400 and torque to be around 700.

Thanks

cmac

dont forget gauges. you will need tranny temp and egt at the least. boost gauge is good to have as well and helps diagnose problems if they come up. you can get there with banks stuff but it will cost you much much more. for the power levels you are looking at i dont think an aftermarket intercooler is necessary but it certainly wont hurt. since you plan to tow i'd look at a dual disk clutch. best option would probably be south bend.
( http://www.southbendclutch.com/dodge.html )

someone will chime in about the rest of the stuff.

Dr Evil

I didn't mention the gauges because the kit comes with them.

Clutch.

I am really happy with South Bend. I have a 700lb ft torque clutch in my dodge

now. I was thinking of upgrading the input shaft to the tranny as well. 1 3/8

as apposed to 1 1/4. My existing clutch doesn't have many miles on it so I

might send it in and have the upgrade it to accommodate the 1 3/8 shaft.

What other ways are there to get to the hp/torque no. I mentioned while still

playing it safe like banks is suppose to do. I don't want black smoke. My

truck diesn't smoke now. I have seen tests on youtube re the tuners and

which ones put out smoke.

patriot pearl blue

I bought my 2002 ho 6speed new, and i really think not only is the spline size different on the clutch, but the over all diameter is different too. Its physically larger in diameter.

So with that in mind, your 5 speed clutch will not work, or will work but not big like the con o fe for my truck.

Not trying to be negative here, but i just dont like my 6speed, too many gears, i hardly need to use many gears with it. I start off in 2nd, skip 3rd drive in 4th and 5th is good to about 40-45 and hit 6th to start "driving" If i am in traffic, its pretty normal to just keep it in 6th sometimes all the way down to 40MPH just as long as i dont try to stab the loud pedal. Give me a powerglide trans that would be nice.

I would think the stock intercooler would be fine for 10 second passes, if you ran methanol or nitrous to keep the intake temps down, the stock core flows very well, add all the power after it and see what you can get away with.

If it were me, i would get a larger turbo hx40 or maybe a new hybrid turbo, some bigger injectors i have the rv 275s and they used to be cheap, a good fuel system and try to control the EGT's so it does not burn up.

BW

Dr Evil

haven't finished readed yet. I have the con O fe. 13 inch clutch.

Dr Evil

O.K. I got it.

bigger turbo,
bigger injectors.

What about a tuner??

I see you point about the shifting. I was going to take the NV4500 and swap it out with the tranny in my jeep. A little overkill, but, that works for me.

Anyway. I figured the stock turbo would need to come out.

Does anyone make a straight reliable complete upgrade kit?? Turbo, injectors,

tuner, exhaust, gauges, intake, exhaust manifolds??

Thanks

patriot pearl blue

I dont know about a simple kit that you would find with normal cars like a mustang turbo kit or a new setup on a camaro.

Maybe find someone with your ultimate goals and go with what they are having good luck with.

My trucks broken, so i have no advise for you right now.

BW

Mike Holmen

I don't know why you need to change from the 5 speed to the 6 speed, the five speed is a very good transmission. To me its a waste of money. You may want to upgrade to the billet input shaft, but its not required. To get 400rwhp, you need to run 90 sized sticks, F1 mach 1.6 or DDP 90's, a edge comp box. If you tow that heavy, your gonna need an exhaust brake for sure. I would upgrade your turbo to a S362 or S364, just cause that's alot of weight to tow. Those sticks are abit hot on a stock turbo, but its do able. The fass fuel system upgrade is a good deal. you probably need to upgrade your clutch. A decent 4in exhaust, and gauges are also nice to get. To get 24 mpgs of one of these trucks, you need a miracle.

nickg

If your towing as much as you say, you should not discount edge J/A or adr. with these you can preset safety parameters so that you safeguard your engine, the box will defuel the truck if you get in over your head while towing and monitor other engine parameters, you can also set low boost fueling to keep smoke to a min, which you cant do if you instal injectors by themselves.

also if your towing, brakes are a huge concern as stock brakes are weak at best, your sig says you have an 02, so that means you can bolt on a set of larger rotors and pads from a third gen truck, (lots of threads on this, just do a simple search ) or as Mike says get an exhaust brake.

after looking over your list, heres the order I'd do it in

Edge J/A (mostly because of the gauges)
Lift pump FASS or Airdog (likely once the J/A is installed you will see that your stock pump is weak or failing)
BHAF
Injectors (80-100hp)
Turbo upgrade (this dept Mike would definately be of more assistance than I)
this should give you more umph than you need and the ability to tune it if required

patriot pearl blue

Before we went to this new fuel, i could drive from my house in kansas city kansas all the way to bowling green kentucky. Its right at 600 miles.

I wished i had access to my old photos, i kept the reciept when i filled the truck up, it got 24.6 mpg because i drive 55-60mph with it on the highway. It really drinks fuel if i drive 70mph. Just thought i would share Its a 4x4 3500 dually with the extended cab and 3.54 gears

I wished i knew that 6 months ago, my rotors were rusted and my pads looked like they were on the titanic.
If i knew the rotors would swap on, i would have looked into it. Instead i bought all new rotors and pads for the 02.

Dr Evil

I don't tow often. I am not a speed shifter. I do mostly around town driving. I am use to shifting slowly. (have driven a Semi) I have an upgraded 13" clutch in my Dodge. Thought the 6 speed would be better I thought for towing.

patriot pearl blue

I think you would be money ahead if you did all the other mods first, and then see about doing the transmission, unless your 5speed is broken.

Having towed with both 5 and 6 speeds (friend had a 2001 5 speed, mine is a ho 6speed) i did not see much difference between the 2 trans other than one less gear.

When towing, neither truck needed to be downshifted for hills. Both drove just fine and the 6 speed is just another gear between the other gears.

As in 6th gear is the same overdrive as the 5 speeds 5th gear. Its not like having a double overdrive.

BW

Beast2B

with 400hp you reduce the need to downshift towing, so I agree that trans/clutch mods should be towards the end of your mod list. do the injectors/box/turbo with the supporting mods (gauges, air filter, exhaust if you want sound).
After trying several set ups, my approach is to use a smaller injector (like the Mach 1.6) along with an adjustable box. Easy to drive towing with the box off or turned way down, but you can turn up the box to play or dyno or race or pull... It will make driveability MUCH better if you don't have to baby the throttle while towing or casual daily driving. My Mach 3s don't give me that level of easy driving without setting my Smarty to half power.

Mike Holmen

Mach threes and those big tires, you'll need more air. Twins would help out lots there. I bet running twins you can drop egt's by 100-150 deg's. What engine speeds you running at for a given highway speed. You could do some water/methanol spray, to help the valve seats survive abit longer.

Just do the five speed fifth gear mod and the fiver will do fine. Its a cheaper transmission to fix vs. a six speed. In the long haul, towing daily driven work truck, repairs will hurt down the road. I used to run mach 6'rs and few different sized twins set-ups. It was a fun truck, but I broke two billet race transmissions the first one was $12k and the second was $8k. Ruined (cracked, burnt out) a few heads and turbos as well. Today, I going for reliablity and some fun. Its still faster than anything that dodge sells and 95% of the trucks on the road. I waxed a pretty good 6.4L ford a week or so ago.

Dr Evil

I see your point. I was thinking that I would try to not beat too much on the transmission as I would like to transfer it into my Jeep. Of course, If I blow it up, I could then rebuild it, buy a new 6 speed and then transfer it to the jeep as a fresh tranny.


Hmmm. sounds expensive, but, maybe in the long run, I won't have to worry about either.

If anyone were going to do the first thing, what would it be.

Fuel injectors, Turbo, Intake and or exhaust manifold, Larger air filter, FASS lift pump, vp44 injector pump??

I would image the FASS should be done around the same time the injector pump is rebuilt. Maybe at that time, I should consider the injectors.

I would think the exhaust should be done when the turbo gets done as well.

Hmmm.

BTW, (alittle out of context) for towing purposes, does anyone have a locker in the rear or limited slip??

I would like to know how to determine if I have a limited slip rear end.

Thanks