My top speed is 65 mph. My case is tagged 3.54 but I have not verified. I've talked to others who have 4.11 gears and they still reach 80mph. I suspect turbo malfunction or pump timing? Upshifting normally produces black smoke. If left idelling for 15 minutes or more, white smoke on upshift then back to black. Fuel Mileage is around 12MPG . When upshifting i feel no extra Turbo acceleration, just a steady increase as RPM comes up. Unfortuanately I have no Tach or Boost gauges to give the experts more information.

Rex McDonald

 

Are you sure you're getting full throttle lever travel when you put your foot to the floor? Have somebody hold the pedal down while you check to see that the throttle lever goes all the way to the high idle screw. You should also check to make sure your high idle screw is allowing max RPM. It should be backed off as far as possible while still being the piece that limits throttle travel. In other words, you want the high idle screw to stop the lever before just before the pump internals do. My truck (see signature) will do 70 in 4th set up this way, and I don't know how fast it goes in 5th.

 

It almost sounds like you have lost boost. check all your air charge lines going to your air to air unit.
Make sure your hoses have no holes in them.
Good luck
Frosty

 

The white smoke at idle does indicate a timing issue. The timing may be retarded based on that info.

As for the top speed there is a problem there as well as you should be topping 80 MPH with the stock settings on the pump as far as max RPM with either the auto or the stick.

As the others have said, check the linkage and adjust for full travel. Inspect the intake hoses and filter for any problems. Spin the turbo by hand and check for any excessive play or signs of oil leakage. Check the intercooler boots for holes or signs of leakage.

After that then have the fuel delivery pressure to the injector pump from the lift pump. You want to have at least 10psi at idle with the stock pump. Low fuel pressure would also cause poor performance.

J-eh

 

I'd say work on the throttle linkage too. Also, do you have an oversize headache rack with that flat bed? I have a huge one, and average 12-14 on the freeway.

 

It might help to go at this, one at a time. Maybe address the white smoke/timing issue first.
Make sure all the rubber boot, boost fittings are all good with no leaks, and the clamps are tight.
Try to pressure test the intercooler by using a large rubber boot with a plugged end and air valve. Run up to about 20psi and listen for leaks all the way from the turbo to the intake horn.
Check the fuel filter/seperator for water. The "water in fuel" light may not be working and you could have water in there... just a though...
Install and or clean your air filter.
Run a good dose of additive through the system too. It can clean up dirty injectors and deposits that build up over time. All can contribute to smoke issues, mileage issues etc.
If you want to tackle the pump timing issue here is a picture to show you the location of the pump timing marks.

bob.

 

Once you resolve the smoke issue tackle the speed issue.
I'll attach a picture showing a common problem. It shows down in the bottom left corner, a note saying "breakover spring". Just above that, is a metal fuel line that inters the pump. Cycle the throttle wide open and make sure that the throttle bracket doesn't hit the line and hang up. If it does, just use a large screw driver and gently bend the line toward the front of the the truck until the throttle bracket clears it.
I'll attach a picture showing that area.
I'll attach one more picture after this on showing the governor screw, idle screw, high idle (governor)screw for you.

Bob.

 

Ok here is the last picture. It shows the various adjusting screws and their functions. If the pump is in stock condition they will all have their tamper covers still on.
You will have to trash them to get them off but that's normal and not a problem.
The guys can help you work thru the various adjustments as you make progress thru the issues.
Don't get discouraged, just go step by step. Remember, it really is pretty much an easy job... it's just the "nervous factor" that gets in the way.

bob.

 

Okay, here's the story. I found the boot connecting my Turbo to the intercooler line had a 1/2 inch hole in it. Dodge has stopped making the boots according to local dealer. Cummins doesn't offer this part as a Cummins part. Local semi dealer has a cummins boot ORANGE that is too long and built differtently but is the same inlet size I think. It looks like I am fabricating, has anyone done this the most correct way?

Additionally, I ran the truck with the intercooler line off for a few. I got lots of engine oil coming out of the turbo is that normal?

 

As long as it's an intercooler boot and the right diameter, you can cut it to length and you'll be fine. I think the oil coming out of the turbo is your white smoke problem. No, that's not normal. Check to make sure the oil return line isn't clogged up before you condemn the turbo.

 

Carquest had a correct size hose that worked great.$6 instead of Dodge $55 the truck pulls hard now and fixed my top end speed concerns. I can easily run 75 plus. Since this is the first driving experiance with full turbo boost, I was very surprised at the amount of black smoke produced under 3/4 throttle & up. I noticed near constant black smoke at 70 mph. Do you think this is indicative of pump timing issue which I have not addressed yet or possibly other ideas?I inspected the pump following pictures provided (THANKS) and noticed that the governor screw was backed out flush with the housing. The cover is still on the "full fuel" screw so does that mean my pump has not been turned up?

 

I don't think the main screw has been turned, but it's very possible that the AFC settings (fuel pin, smoke screw, star wheel) have been played with. I wouldn't want it smoking all the time at speed, a little smoke at heavy throttle is OK, though. Look in the FAQ section at the pump tuning instructions, that will explain how to adjust the AFC settings. I see you have some Banks stuff on the truck, does that include the turbine housing or do you still have the stock 18.5 cm one?