Coast Resorts Open Roads Forum: Tow Vehicles: 2006 Dodge 2500 5.9...a few upgrades

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Topic: 2006 Dodge 2500 5.9...a few upgrades

Posted By: Rbertalotto on 12/22/16 04:48pm

Well, it started out being a bit expensive and it ended up being a WHOLE BUNCH expensive......$12K ended up being just shy of $20K !!!!

I have a 2006 Dodge 2500, 4X4, 5.9 Diesel with 165,000 miles on it. Looked at new trucks and simply didn't want to spend 60 large, and I like my truck. It just needed some love.

Originally I decided to have a bunch of BD Diesel stuff installed at Auto Werks Diesel in Caldwell, NJ. They are 4 hours from me but came very highly recommended. I've read articles about them in various diesel truck magazines over the years.So I decided to take the truck down there for the following:
BD "Built" Tow/Haul Transmission
BD Torque Converter
BD Exhaust Brake
All new radiators (4)

All of that came to $12K with labor and other ancillary stuff......

But when we started to take the truck apart....the phone started to ring!

"Hi Roy, I have a bit of bad news....."

Transfer case had a hole in it and a crack....
Replaced with a Jasper Xfer case...Sure is pretty!

Oil pan had a rust spot nearly through and a big dent and a crack
Replaced with new version of OEM, thicker...Required longer bolts......Almost as pretty as the Xfer case!

"While we are in here....You should...."

Replace front and rear main seals on engine. They are weeping.
Replace Flex Plate. Crazy not to do it considering what you are spending now!
Replace Water Pump..Why not!
Replace Idler
Replace Serpentine belt
Replace front sway bar bushings and rod ends with VERY pretty BD Diesel version...
Replace rusted cross member for transmission
Adjust the valves (160K miles and never done. They were quite a bit out of spec)

So I picked the truck up and drove 5 hours to get back home.......To say that Auto Werks did a great job would be an understatement! They guys are artists!

The verdict?

FANTASTIC!!!!!!! Worth every penny! I can't believe how nice the exhaust brake is. Feel like an 18 wheeler!

The new transmission shifts velvet smooth. Hard to tell a 2nd to 3rd and 3rd to 4th shift.....

Have no idea why, but I checked my mileage twice and I'm getting 2-3mpg better. From 17mpg to 20mpg! Could the valve adjustment be responsible?

Engine temperature is 10 degrees cooler and transmission temperature is 20 degrees cooler. Can't wait to pull the big trailer to see what happens.

Another strange thing is I'm not using anywhere near the amount of boost I used to. My Juice With Attitude is set to warn me at 30 psi. In 5 hours, never heard the alarm go off and I "got Into It" a few times....This truck simply hauls a** when the JWA is set at "Race".....

Yup, lots of $$ to spend on a 10 year old truck with 160K miles, but a new one is just shy of $65,000........Hope I get another ten years and 160K miles....That will only be $2000 a year!

Merry Christmas!

RoyB
Dartmouth, MA
2021 RAM 2500 4X4 6.4L
2011 Forest River Grey Wolf Cherokee 19RR
520 w solar-200ah Renogy Li-Epever MPPT

Posted By: 1320Fastback on 12/22/16 05:04pm

Cummins powered trucks are always worth putting money into and you certainly can't go wrong with BD.

Mines much older being a '92 but still spend money on it and have no plans on upgrading, especially not to a DEF model truck.

1992 D250 Cummins 5psd
2005 Forest River T26 Toy Hauler

Posted By: Rbertalotto on 12/22/16 05:07pm

Thanks...Totally agree. In fact, I wish mine was an older 12V....Even simpler than my 2006!

Posted By: austingta on 12/22/16 05:08pm

As long as you're happy, more power to you! (See what I did there?)

Merry Christmas!

Frank Brooks Austin TX
2018 F 150 King Ranch max tow package with 3.55 gears
Published towing weight limit 13200
Payload per sticker 1464

Posted By: Rbertalotto on 12/22/16 05:10pm

Thanks Frank!

Posted By: 1320Fastback on 12/22/16 05:17pm

Rbertalotto wrote:

Thanks...Totally agree. In fact, I wish mine was an older 12V....Even simpler than my 2006!

Doesn't get much simpler than a 1st gen. We have 3 sensors, none of which are needed for engine operation and with a gutted FSS it will run until I turn it off. You literally could bump start the truck and drive across country without a electrical system at all providing you have a manual trans and don't need headlights or brake lights.

Posted By: Rbertalotto on 12/22/16 05:20pm

Yup, my dream is to put a 12V in a 1962 Step Side Chevy/GMC Pickup....Perfect looks and the perfect motor!

Posted By: romore on 12/22/16 05:38pm

That would be fun to do on our 05 but is more than a little beyond reach. A local 66 International 4x4 has a nicely installed 5.9, you want to see the looks that truck gets. [emoticon]

Posted By: Rbertalotto on 12/22/16 05:43pm

And of course an M53 Power Wagon with a Cummins....

[image]

Posted By: path1 on 12/22/16 05:53pm

Glad your happy!!

I love our exhaust brake on mountain passes. We can go Seattle to Yuma and not touch brake other than city traffic no problem.

But one thing did go wrong with exhaust brake. And after talking with BD, not an unusual problem. One of the brass plug bolts vibrated out. He recommended one of two things to make sure there are no problems.

(1) scribe a mark with nail or something, so can tell if a bolt is vibrating out. The index mark on bolt should stay put.

Or (2) and this is what is did. Rigged the bolts up like aircraft safety wire so they can't come out. I used a Stainless steel rod. Better known in real life as bicycle spoke.

Bolt vibrated when we were on mountain pass, wife still talks about how much racket it made, she thought it was going to blow up. It did burn a hole in insulation right above trans dip stick.

link has pick of what "safety wire" is https://en.wikipedia.org/wiki/Safety_wire

And pick up spare Serpentine belt, but the size that does not include A/C in case compressor freezes up. Should be belt routing sticker under hood for a/c and no a/c.

I'm coming up on 125,000 (I think) on a 2001. Being it is getting older we travel with OEM "service manual" and "part look up" book on desk top of our computer. Helps with mechanics that just want to throw parts at what they think is problem. Really helps when something happens on the road and you're away from you're regular mechanic. IE... at mercy of some dealer or mechanic in middle of nowhere.

And like you it will be along time before I get separated from my $$$ on a new truck. Not to mention if you do break down you're RV makes a handy place to stay in while problem getting fixed.

My next upgrade is your trucks generation of brakes. Or a spare VP44 under the seat. Can't decide which yet.

Only bad thing about older trucks is what my brother in law is going thru right now. He got rear ended in his 97 Ford with a 7.3 and is afraid insurance company will "total" it out. And he does not or need new payments on a new truck right now.

Glad you're happy.

Another good looking oldie

http://helpamericanheroes.com/blog/watch........the-johnabilt-in-a-neighborhood-near-you

Posted By: path1 on 12/22/16 06:05pm

romore wrote:

That would be fun to do on our 05 but is more than a little beyond reach. A local 66 International 4x4 has a nicely installed 5.9, you want to see the looks that truck gets. [emoticon]

Sounds great.

Post a pic

Posted By: 352 on 12/22/16 06:18pm

Rbertalotto wrote:

I was going to comment, but I will keep your bubble intact. If your happy does not mean the wife is happy. Getrdone and HO HO HO Merry Christmas

The manatees of Halls river Homosassa Springs Fl

1985 Chevy Silverado c10. 454 stroker / 495 CI = 675 HP. 650lb of torque. Turb0 400 tranny. 3000 stall converter. Aluminum heads. 3 inch exhaust flowmasters. 2 inch headers. Heat and air. Tubed.

Posted By: Rbertalotto on 12/22/16 06:22pm

Wife spends more than this on shoes and hair dresser!

Posted By: Durb on 12/22/16 07:54pm

I agree with your decision to repair and improve an older truck. The lines on the 06 will look classic for many years to come. My 04 has only 81k miles so it is just filters and fluids for a while but I have made the commitment to toss money at it when things start to go. I can't imagine expenses any higher than depreciation losses on a new truck.

Posted By: ScottG on 12/22/16 07:57pm

The valve adjustment (not required until 150K) probably didn't effect your mileage but the BD torque converter is more efficient and gets more power through it even when not locked-up. That may have helped. That is a great performing trans after it's totally upgraded like that.
Enjoy the "new" ride!!!

* This post was edited 12/22/16 08:03pm by ScottG *

Posted By: romore on 12/22/16 08:25pm

Rbertalotto wrote:

And of course an M53 Power Wagon with a Cummins....

[image]

I LIKE THAT!!! No speed demon without an over drive but can you just imagine the torque?

Posted By: campingken on 12/23/16 10:43am

We bought a 2001 Dodge 2500 reg cab 4x4 5.9 from one of the forum's members (Me Again) that he had built (trans, torque converter, programer, etc.) to tow their large 5th wheel. It is a towing beast compared to our puny stock 2003 3500 5.9 (235 hp and 460 pounds of torque)

The 2003 has 175,000 miles and the 2001 126,000. Based on the price of new diesels we plan to repair them as needed for another 10 years,

Ken & Kris + Heidi the dog
Sequim, Wa.
2003 Dodge 3500 SRW 4x4 diesel
2017 Trails West Sierra Select 2 Horse slant load trailer

Posted By: IdaD on 12/23/16 11:44am

Again I question why some think a new diesel costs $60k.

2015 Cummins Ram 4wd CC/SB

Posted By: Grit dog on 12/23/16 11:44am

That old PW is one of the sweetest trucks I've ever seen!!

2016 Ram 2500, MotorOps.ca EFIlive tuned, 5” turbo back, 6" lift on 37s
2017 Heartland Torque T29 - Sold.
Couple of Arctic Fox TCs - Sold

Posted By: Grit dog on 12/23/16 11:49am

Nice upgrades to your 06 as well!
Go roll some coal now!

I'm on the fence about my 07. Keep thinking of upgrading, but it's built right and realistically isn't going to need more than new seat covers, front end rebuilt and maybe AC or alternator in the next 100kmi.
Although, I have an almost 14 year old. He will be driving in a year and a half about. Maybe should "keep it for him" and go buy a newer one too!

Posted By: Me Again on 12/23/16 12:11pm

Rbertalotto wrote:

And of course an M53 Power Wagon with a Cummins....

[image]

Looks like a 4BT Cummins. Chris

2021 F150 2.7 Ecoboost - Summer Home 2017 Bighorn 3575el. Can Am Spyder RT-L Chrome, Kawasaki KRX1000. Retired and enjoying it! RIP DW 07-05-2021

Posted By: Me Again on 12/23/16 12:13pm

campingken wrote:

I drove that old RAM a few times? Ran pretty sweet! Chris

Posted By: FishOnOne on 12/23/16 02:02pm

$20k in repairs/ungrades.... YaawwwZaaaa....

Enjoy... [emoticon]

'12 Ford Super Duty FX4 ELD CC 6.7 PSD 400HP 800ft/lbs "270k Miles"
'16 Sprinter 319MKS "Wide Body"

Posted By: Rbertalotto on 12/23/16 02:04pm

Quote:

$20k in repairs/ungrades.... YaawwwZaaaa....

It's only money!

Posted By: rhagfo on 12/23/16 03:24pm

campingken wrote:

Wow, both low mileage, we plan on taking our 2001, 2500 4X CTD into retirement at 297k and running good.

Russ & Paula the Beagle Belle.
2016 Ram Laramie 3500 Aisin DRW 4X4 Long bed.
2005 Copper Canyon 293 FWSLS, 32' GVWR 12,360#

"Visit and Enjoy Oregon State Parks"

Posted By: 352 on 12/23/16 05:17pm

2000 Dodge 2500 5.9 with camper package ( equals a full one tone ). Bought it with $6500 with 162,000 miles 3 1/2 years ago. Now have 220,000.
This is what the major items I did since.

1. Transmission. Billet torque converter stage 1. Heavy duty clutches and disks. Torque converter lock up switch. Recalibration kit in the tranny. All new bearings. Labor included $2000.
2. Injection pump. 2 year warranty and Fass 150 GPH lift pump ( lifetime warranty ) labor included $1950.
3. New radiator, water pump, clutch fan and exhaust brake. Installed $700
4. New rotors, calipers, and back shoes. $400 labor included.
5. Power Puck. Not a programmer but adds a little boost when needed. $200

Most all parts were OEM Mopar and a labor rate of $50 per hour. Buy a new one WHY

Posted By: ScottG on 12/23/16 06:17pm

Wow 352, that is a seriously nice second gen.
You just dont find them or even third gens like that. Most have been used hard and even if they drive great, they look like hell.

Posted By: The_real_wild1 on 12/23/16 07:12pm

Sounds good as long as you like the truck and keep it for as long as you have planned.

Posted By: Rbertalotto on 01/13/17 03:36am

So it has been a few weeks since I got my truck back. All I can say is it is fantastic. I'm not sure what part of the modifications caused the most improvement. Fuel mileage increased by nearly 3 miles . Haven't had a chance to pull the trailer yet but simply driving around on the highway and in town has been great. Big cross country trip coming up in February. That will be the test.

Posted By: Dave H M on 01/14/17 11:35am

IdaD wrote:

Again I question why some think a new diesel costs $60k.

if you find out let me know [emoticon]

But After all it is just money. [emoticon]

Posted By: Nevadastars on 01/14/17 02:39pm

I also cannot justify the price and complexity of the newer diesels, so picked up a very clean, well maintained, one owner 2007 5.9 Cummins Ram 2500 QC short bed 4x4. It has 155k on the odometer, but the trans has been rebuilt as has the front end which are the most common issues with these trucks.

So, far I have upgraded the stock stereo to a Pioneer Navigation head unit, Air Lift bags with on-board compressor, leveled it with Bilstein shocks and have the hitch rails for our future 5th wheel trailer. I also ordered leather to replace the cloth seats from leatherseats.com. It should be here Tuesday. Once our MH sells, we will be ready for the fiver.

2016 Forest River Wildcat Maxx 262RGX 8,268 UVW 11,754 GVWR
2007 Ram 2500 QC SB 4x4 Smarty tuned 5.9 Cummins
B&W Turnover Ball & Andersen Ultimate

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