There was a BIG differance in power between my 2003 & my wife's 2006. The turbo, downpipe & exhaust really restrict the early common rails. Swap on the later model stuff, add a programmer & have fun.

 

The Triple Dog crazy larry program doesnt do anygood on the 04s. When I had the Tri Dog I was told the best program for the 04s was 2.38 and that felt more powerful on my truck tan crazy larry But my Quad & Van Aaken stack makes better power. What works well on one truck may not work on the others.

 

My 04 (as well as several others) sure run like dodo. LOL

 

For one thing you comparing an auto to a 6-speed which you can't do, but something is wrong with his truck, or yours has more work done to it then you know of (did you buy it used??).

Simply put if your running a stock 3g against a mod'd 3g, then the modded one should win everytime (or there is something wrong). I will probably take some heat for this one, but 6-speeds are not as fast as autos unless you have a guy that knows how to race a manual diesel (not the same as a manual gasser) and the truck has ALOT of clutch to hold up to the abuse...

 

Does he have any gauges??? Are his EGT's high? What is his boost pressure? if he has any boost leaks (damaged hoses) the engine won't see enough boost to allow the computer to fuel properly...

 

The Triple Dog on extreme made only 66hp over stock on my '03 305/555. This was with a big turbo, aftercooler, FASS, and some other stuff. Same mods, Triple Dog on tow with a little TST thrown in made 555/960 uncorrected.

Smarty alone with same mods made 135-ish over stock.

For some '03-'04 trucks the Bully Dog is worthless. Certainly the least HP per dollar of ANY electronic power adder I have purchased. (And I've been through many)

 

2004 has 2 fueling events occur and the 2004.5 has 3 fueling event's that occur and the 04.5 has a catalytic converter
those are what give the 610 the extra ponies.
Maybe a few other little tweaks to.