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SFX needed a BIG truck!

Enter one Ram 3500 Diesel Mega Cab DRW 4x4!

Welcome to our Dodge Ram project page. Articles on installation and aftermarket parts, including accessories and sharing our reviews and more.
Looking for aftermarket parts for your Dodge Ram click here


Article Segments:
Ram 3500 buying guide
Replacement light bulb guide

 
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When you need a tow vehicle... GO BIG!

10/23/2010:

We were needing a tow vehicle to pull one of the show cars out to Las Vegas. We needed a big truck to do the job and had searched around using Ebay and Autotrader. No need to buy new, because with this economy who can really afford it. Plus, we were looking at diesel trucks for the huge torque abilities of the motors. Diesel engines are hardly broke in at 50K miles, so it didn't have to be new. We looked at Chevy's and Ford's, but settled on a Dodge Ram series due to the Cummins motor.

Now, we really just needed something that could pull 7K lbs, but why just get the minimum? We started looking for a 3500, then Dually. Sure, why not? Leg room, heck yes it's going to be a long trip. So, the final search was for a 3500 Diesel Mega Cab Dually. Wait, what if we have to go somewhere off-road when the zombie outbreak happens? Ok, add in 4x4 and we're set. That will definitely get the job done and save our butts when the undead walk again.

Finding one in good shape proved to be a little difficult. Seems most have that dreaded ball hitch in the middle of the bed and you just know it's most likely been used hard. The few we found locally had been roughed up on the farm or on a work site. Not that it's a bad thing, as that's what they are meant for, but we were hoping for something a bit more virgin. We got lucky on the way back from a dealer Sherman and found ours at Dodge City in McKinney. The sales guy Lou stayed late for us and we drove it home Saturday night.

10/24/2010:
Come daylight the inspection begins and nothing was overlooked. The bad was minimal and the good was this one had never seen a gooseneck hitch. Only bumper pull only, if ever really used. This is great we found a toy hauler that was status only and never abused. Everything was great till the dreaded heated decision of manual veruses automatic. See this Ram is manual. I myself have always had manual cars and auto trucks, so I was hesitating on this. Automatic is so much easier when towing. Yes, I know the arguements for stick and truthfully it came down to the following. Blow up an Automatic transmission and it's an expensive fix. Toast a clutch, well that sucks but it's not going to break the bank to fix it.

That decided we made the arrangements with the dealer to get some minor things checked out and fixed, while they got all the paperwork in order.

10/27/2010:
She's ours now!

10/28/2010:
First thing is we have pull a 2100 lb trailer with a 4100 lb car almost 1200 miles. Some of it up and down steep grades, that means we are going to need a brake booster for the electric trailer brakes. We prefer to use Tekonsha and they have a new Prodigy P2 controller. Now the easy way is just to get the wiring harness adapter, plug and play the easy way.

Also, some of us aren't 6.5 feet tall and our short legs are having a bit of trouble getting in. It's a big step in. That's an easy solve with some step bars. Now, there are a lot of choices when it comes to step bars, nerf bars, or running boards. However, you want to call them. You've got Chrome, Black and Stainless steel. There is also, 3 inch diameter or 4 inch, there is 4 inch oval or 5 inch oval. Cab length or Wheel to Wheel. I've always looked at it like this, how do you make a sandwich compared to someone else.

I've chosen to keep it simple: Promaxx 3 inch round cab length in stainless steel. That will allow everyone to get in with some ease and keep it inexpensive. Also, Chrome and black can chip. Black can be repainted, but if it's stainless then no rust or retouch.

Summary:

  • Total Mileage at time of purchase: 88,124
  • Came with BF Goodrich All Terrain T/A LT265/70R17 (Oops, there is an issue see 01/21/2011)
  • Bed already has a LineX liner in it.
  • Has Dee Zee Diamond Plate caps on the bed
  • 4 Pin already in place for the small trailer, comes with 7 pin.

11/10/2010:
The fuel door that is aftermarket on the vehicle, has some chipping and flaking to the chrome, so we are going to replace it with an Allsales fuel door and add a locking option ALS6041CL. Also, this truck came already with Putco Door Handle Covers and Tail Handle Cover.

11/12/2010:
Was talking with one of our vendors who had his Trailblazer SS stolen a few weeks ago. He just replaced it with a Chevy Silverado 2500 Diesel. I told him about my new truck and we started talking diesel. He told me about the DPF deletes and programmers, which he's already done on his. Night and Day difference. Emissions legal not really (check your state), but the DPF retricts the system so you burn more fuel which adds more CO2, so if I burn less fuel I add less CO2 which is greener. Hmmm, I think the DPF needs to be removed. I would rather get better mileage. So soon we'll add a Flo-Pro exhaust to it part # FLPSS636 With that we need to add a programmer that adjusts for the DPF delete, so include one H&S Mini Max part HNS109003.

11/13/2010:
Future modification when the brakes are finished. I've got about 3mm left on the fronts and I'm going to try some SP Performance rotors with the reboxed Hawk pads. Part numbers SPP53012F for the front, SPP53011F for the rear, and the pads are front SPPMD965 and rear SPPMD702A

11/24/2010:
Ok, so I've poked around the forums and did some research. There appears to be only three programmers common to Dodge guys that work with a DPF delete. The Mads Smarty, H&S Black Maxx and the Edge Juice W/ Attitude CTS Race. I found out the the Black Maxx is built on the core of a Bully Dog system, which is a good product. I thought, that I would try the Edge, as it comes with a turbo timer and option for backup camera. I'm just waiting for it to come in next week and I'll pick up a Flowpro DPF delete pipe part # 27113 instead of an exhaust system, as I'm debating on installing stacks.

11/27/2010:
Went to the shop today and took apart the air intake system up to the turbo. I'm thinking of building a custom intake instead of an off the shelf one. We have some Spectre parts that were used on the Camaro till using an SLP Cold Air kit on it. These parts are 4 inch modular pieces. I think with a couple more I can fab an intake together instead of using a K&N, Airaid or AFE. Well, the more I thought about it and looked at it. I realized that I was going to fabricate something to make the MAF sensor and air sensor fit it really, which isn't going to be worth the trouble, nor would it save money. I'll just use an off the shelf kit.

12/01/2010 in front of the shop.

12/01/2010:
The Edge Racing Juice 31305 showed up today. Definitely excited about installing it.

12/04/2010:
Started the installation of the Edge Juice at noon today in the driveway. The firewall rubber grommet just pops out, so it's easy to remove and at the end of the install you just cut a slice it to tuck the cables into and replace. When connecting the turbo timer I found it easiest to not only remove the panel but the metal kick plate as well. Ran the wire for it down through the plastic ring that held other wiring. By 1pm had gotten up to the Pyrometer install and started having some difficulties. Basically, the cordless drill I was using was too big for the area. Had to switch out to a smalller one. Also, double and triple checked the location before tapping a pilot hole, which of course then the 1/8 drill bit snapped. Finally got the hole done at about 4pm and said to heck with it, as over the course of those 3 hours I had been interrupted a few times by the wife, in-laws and kids since I wasn't doing anything important.

Some people recommend running the motor during the final drill through to keep the shaving out of the manifold and from entering the turbo. Be sure to wear safety glasses if you try it. I did it with the motor off, if your careful and cleaning away the shavings while drilling then you won't get but a few inside. Canned air is a good way. Those small leftovers can past through or you can use a magentic wand to try to remove them.

12/05/2010:
Began tapping the threads for the Pyrometer. Never did this kind of installation before and it's a pain in the arse. Threading a hole, by hand at an awkard angle is killer. After two hours and little headway I gave up. Hand, wrist and shoulder were sore. I did more research and asked questions on the online forum. See your supposed to do this by hand, so as not to muck up the threads your cutting and put less wear on the threading tap. Well, with the angle while trying to use a ratchet is difficult. Most people I found out end up using a power or air drill and then do the rest by hand once it starts to bite.

12/08/2010:
Two days of "No way am I working on it in they dark and cold once I get home", resulted in having to leave work early to get it running. The wife wants to park her car in the garage, which I was blocking entry too. It's wired and it runs, but haven't finished installing the Pyrometer or the DPF delete pipe. At least the weather was better. I'll take it to work tomorrow and finish the rest there on break or after work.



     

12/09/2010:
Ok, finished up the threading in 20 minutes thanks to the cordless drill. Installed the pyrometer and started looking into removing the DPF. There are the three sensor locations for the replacement sensors. Before Cat, after Cat/before DPF and last one after DPF. The H&S programmer I'm told just shuts these sensors off and bypasses them, so you do not have to use the replacements. There are two long pipes that are connected before and after the DPF. I found out these are connections for the Barometric Balance sensors which route up to the transmission. You disconnect them from the tranny...... More to come later.

12/16/2010:
The O2 sensor just wont come out, so till I get a replacment to put in, then DPF can stay put. Otherwise, I'm having a blast with the Edge. Only taken it to 2 so far but a big difference in power.

I've also had people ask me on the forums about the mud flaps and I've found that they aren't Mopar, but actually are Huskyliners. Part # 57121 and part # 56071 for the front, but they don't work with the flares.

12/27/2010:
I just took a call on someone asking about what special conversion needs to be done to run a standard diesel motor on bio-diesel. About o-rings and other things leaking. I haven't heard of anything except how a friend caused himself problems years ago running homemade bio-diesel, so I had to read up on some of this to learn more and thought I would share.

Here are links to Wiki's information and the Government's take on it. Basically, you can use B2 and B5 in a normal truck and it doesn't void the warranty or cause problems. B20 and B100 require practiced modification of the fuel see an opinion here, which is why it's use isn't covered by the manufacturer.

1. Bio-Diesel does require replacement of o-rings that are already worn in older vehicles. You just need new ones and nothing special. Mainly as the bio-diesel has more lubricate to it and can cause leaks with worn rubber gaskets and o-rings.

2. Conversion kits are not needed, biodiesel can gelatinize and we all know how hard it is to suck jello through a straw. The conversion kits apparently just warm the fuel so it flows and that's all.

3. Dirt and other particulates can be attracted to bio-diesel and stick to the fuel and can gunk up the fuel filters, so till you clean all the gunk out of your tank and lines you can stop up fuel filters.

Remember Rudolf Diesel's engine ran on peanut oil.

12/29/2010:
Replacement grill shells are not the same as billet grill. I cannot tell you how many people call or order a billet grill and then are disappointed that they didn't get the shell with it. We get calls on these a lot and we used to have a source for the shells, but it dried up and dealers are expensive.

I know, that I have been needing a replacement for the Ram, as the chrome is peeling and flaking off from rock chips. I was going to just take it apart, sand and repaint using Krylon. However, now thanks to us finding Paramount we have an option again. See part PAR420347 for you Ram guys needing a replacement. Comes 4mm or 8mm bars or even vertical 4mm & 8mm or mesh.

01/20/2011:
Gas mileage, well fuel mileage I guess you might say. Anyway, I've did the calculations and it's about 10 to 12 mpg towing (+7200lbs), and about 14.3 to 16.3 mpg in the city/hwy. Some of that depends on the setting and how I've been driving it. Remember I haven't removed the DPF yet. O2 sensor is seized in the threads and I'm going to have to replace it (5149263AA) when installing the bypass pipe.

01/21/2011:
Those front tires really look small. It annoys me. Hmmm.... maybe 285/75R17's. Well, 2 hours of research later it seems I might finally understand things. See the factory size is a 265/70/17, which is what is on the truck at the moment. The problem is that the BFG's are only making a load rating C anymore, they used to make a E but that is not available and might be replaced with the Rugged Trail T/A of the same size. FYI, that is the stock size of a Tundra.

More weight equals greater effort to stop and start, which will hurt gas mileage in city. However, if you do more hauling, then less revolutions per mile is what your looking for which reduces rpms and saves fuel. That is why semi trucks run large 22.5 wheels with tire diameters of 36.3 to 36.9. That gives them overall better fuel mileage on a haul, but suffers in city stop/go traffic.

Here is a chart with some links I created to help out, if your looking like I am to figure this all out.

Dodge Ram 3500 Dually Replacement Tire Options (Nitto & BFG are only 2 options out of many)
Tire Size Diameter Weight Revs per Mile
235/80/17 Nitto or 235/80/17 Hankook 31.60 43 lbs 657
265/70/17 Nitto or 265/70/17 BFG 31.61 41 to 48 lbs 657
285/70/17 BFG or 285/70/17 Nitto (requires spacers) 32.71 54 to 56 lbs 634
255/80/17 33.3 46.3 lbs 625
285/75/17 (requires spacers) 33.86 61 to 70 lbs 614
315/70/17 (requires spacers) 34.36 61 to 70 lbs 601

Special Note: Dually tires cannot rub against each other in the rear. That heat and friction will cause the tires to wear and burst. Spacers are recommended in larger width tires.

Now, I know that there are conversions from to the 19.5, 22.5 and 24.5 semi wheels for all dually trucks. Yes, it looks cool, but unless you are doing a lot of highway miles then fuel is going to kill you. The mass and weight of these wheels are about twice that of factory, which means your fuel mileage in city will drop by half, but improve by the same maybe on the highway. The tire wheel/tire setups are very expensive, yet pay off if you are racking up the miles, as the tires will last you about 250,000 miles. A normal set of tires last only for 30k to 50k miles.

02/20/2010:
Ok, finally got the replacement O2 sensor for the DPF filter part # 5149263AA from Mopar yesterday. This morning was perfect to start work on getting the Flo-Pro delete pipe part # FLPSS636. The Barometric connections to the tranny had to be cut. I just couldn't get them to come out. Its just rubber hosing and I will plug them later. The DPF came off with little trouble. Had to undo one of the muffler rubber hangers to get it to twist and come free. Went to install the delete pipe and realized things were not lining up as to hanger and sensor. Tried putting the 3 bolt bracket on the front of the lower catalytic and realized the pipe replaces that lower catalytic, as well as the DPF filter. Ok, unbolted the cat and dropped it out. However, I had no hardware for the delete pipe, so a quick run to Lowe's and some 3/8-16 x 1-1/2 Hex Cap Stainless bolts, nuts and lock washers. Hillman part # 8820201, 881772, and 882062. I get back and hang the pipe up on the bracket next to the flange that it bolts too. Then slip fit it into the extension pipe out from the muffler, which I had to put back into place. I bolt up the delete pipe and plug in the O2 sensor. Did my final check and was done. I'll post pictures shortly. I fired it up to check and she sounds like the engine is reving more freely, but of course. I've topped off the tank, so to get mileage calculations.


If your state has emissions testing then this will make you fail. It's for off-road use only, as it deletes part of the emission system.

02/24/2010:
A surprise is showing up tomorrow. While waiting we had rain today and it got me thinking the wipers were kind of toast on the truck. I replaced one with a RainX Latitude (RAX5079280) and the other with a PIAA Si-Tech (PIA97060). This way I can find out which one is the better wiper, my bet is on the PIAA. The Dodge Ram uses 24 inch blades on both Drivers and Passenger sides.

03/01/2010:
Well, I've gotten the done the surprise mentioned before. The truck now has twin stacks from Grand Rock/Powerflow on it. These are 6 inch Chrome 6 Inch stacks GDRSA6-36SBC and the install kit GDRDPU-6SK. The install wasn't too difficult just remember measure twice and cut once. The first step was a test fit of the y-pipe in the bed. No trimming of the main slip pipe was necessary, as it could have been to get the stacks to space off from the bed rails. I marked out the where the hole was to be in the bed. Next was getting the hole done as it would intersect with a cross member, so a plasma torch was the easiest way to cut through the bed and the cross brace. Cleaned it up some, but part of the Line-X was bubbled up and we might need to make a plate to go around the area to give it a cleaner look. The U bolt hangers were marked and installed to carry the weight. Since one end of the U bolt ends inside the cross piece we could only bolt one side. Next was the fit and mounting of the stacks. That wasn't too difficult. Finally the connection to the exhaust. We took the rear exhaust out from the DPF pipe back and worked the exhaust off over the axle forward. Then it was just a simple connection of the pipe coming down from the bed to the exhaust system. Cleaned and tightened everything, then fired her up. Sounds great!


 

03/06/2010:
The ride is getting on my nerves. The shocks in this feel every groove and transmit it while boating up and down like a 66' Deville. I think the shocks are worn out and needing to be replaced. Most of the Dodge guys seem to like the Bilstein 5100's, so I'll get some ordered in. BIL24-185776 and BIL24-191203 are the shocks. Maybe a BIL33-170794 as well, which is a steering stabilizer.

03/17/2010:
I've been reading up on chicken lights (running lights) on the Cummins forum and have found some interesting installations. A lot have mentioned the use of Recon lights, which used to get, and for awhile didn't but we now have a distributor for them again. I started poking around on their site and found REC26414X, which is cool.

03/17/2010:
Ok, we all know that if you have a dually then the front wheels kick up a lot of rocks and other stuff which hits the flares or step bars causing all sorts of chips and scratches. This ones no different it has close to 100 small chips on each of the rear flares mainly due to the angle. I'm thinking of Rhino/Line X on the front under the body line to cover them up and avoid more. Doesn't solve the step bars, so this weekend while at a trade show starting talking with the rep for PowerFlow. I was wanting a fitted one, but with the front Bushwacker flares no options really exist. He suggested their Big Mudder line of products. Part # PFL3103 seems to do the trick nicely. I'm going to add to the rear ones to match. I need to re-secure the Huskyliners as they were installed to good and are somewhat loose. I'll use the PFL3104 for the rear. Posting pictures in the next couple of days.

03/17/2010:
Time for new brakes. The squeal came back from when we bought the truck and I was getting sick of it fast. I put on SP Performance front rotors SPP53012F and the pads are SPPMD965. Not a hard or especially difficult install, but time consuming and requires some brute strength. After removing the wheel there are two bolts which hold the caliper to the carrier and then you remove the two bolts for the carrier. Take off the hub extension. You don't have to worry about removing the castle nut. Bang on the rotor to loosen it from the seat. Clean some of the gray zinc coating from where the pads will contact the rotor. It can make the pads squeaky if left on. Install the new rotor, pads and reattach the caliper. Remember to use some Loctite® 263™ Threadlocker on reattaching the bolts. Don't need to over torque. A little clear lube will get the pads on the clips easier and if you smear residue on the back of the pads where it seats to the pistons it helps. I also inspected the suspension and I believe it has the original shocks still in place. Also, that has causes some bushing wear to the end links on the sway bar and they need replacing. Maybe Tuff Country 30927.


04/11/2010:
Intake arrived today. Decided to go with a AFE part # 75-11342-1 and it works on both the 5.9L and 6.7L engines. Installing wasn't difficult at all. Be sure to have the radiator bracket on the bottom and not the top. I had to flip it around once I got the box in place. Also, the easiest way to tighten the bolt/nut on the fender side of the new air box is to loosen the fender liner. No other way to really reach it otherwise. Use a open end of a box wrench to hold the nut and ratchet with the other hand. Also, before putting the air tube into place make sure to install the crankcase breather tube along with the sensors. Remove it from the factory tube by clipping the factory clamp off, nearest the factory intake tube, this way you have the nib in place for inserting into the gromment on the new tube. A little WD-40 on the inside of the reinforced hose helps lube it to slip on the turbo inlet. When you reconnect the sensors make sure you hear the MAF click into place and lock it with the red tab. After that your done.

I've noticed a difference in the intake temperture already. It's about 20 to 30 degrees cooler, than with the stock intake box. I just filled up, so we'll see how it improves the fuel economy. I've been getting 14 to 15 mpg, but that is a city/hwy combo. If just highway, then I'm getting closer to 18 mpg. If you have a 2WD, then I bet you can add about 3 to 4 mpg to those figures. I've also found that I have the short air dam under the bumper. Apparently there is a taller version and I'm thinking about swapping it out, so less air turbulance under vehicle should help fuel mileage.


 

11/21/2010:
We are thinking of selling the big beasty as we're just not using it as much as planned. $28K is the asking price,
$27K without out the programmer, air intake, delete and stacks.

She has 102,700 miles and you can call and speak to Richard. Either assume the loan or buy outright.

 


Taken just after we bought it.

Taken at the Hoover Dam.



       

Holiday Coupon from SFX: With Google Checkout get 10% off with purchase of $400.00 (coupon code: dieselfreak)

Baseline Ram 3500 Mega Cab Dually 4x4 Lariat information
Original Retail Price (MSRP): $57,430 we're guessing, as we paid just a little over half in used condition.
Compression ratio: 17.20 to 1
Bore & stroke 107.0mm x 124.0mm (4.21" x 4.88")
Engine:  6.7L Inline 6 Diesel Intercooled Turbo 24v
Transmisson:  6-speed manual G56
HP (BHP/RPM)   350 BHP @ 3000 RPM
Torque ( Lbs-Ft/RPM)  610 lb·ft @ 1400 RPM (Automatic is 650 @ 1500)
HP to Weight Ratio   
Front suspension: High-mounted, double-wishbone front suspension and stabilizer bar
Rear suspension:  Dual Rear Wheels
Brakes:   
Wheelbase:   160.5 inches
Length:  247.7 inches
Width:   79.5 inches
Height:   79.4 inches
Curb weight:   lbs
GVWR 5570 lbs
Max. wading depth   
Front hiproom   64.9 in
Front shoulder room   67.0 in
Rear hiproom  64.4 in
Rear shoulder room  66.5 in
OE Wheels/Tires:   Tire LT265/70R17 or LT235/80R17E
Payload/Towing Capacity  15,850 lbs
Replacement Bulbs  See Below
Fuel Capacity, gals  34.0
Estimated fuel economy   
Current Fuel MPG with Mods   14.6 City
0-60 (sec.)    
1/4 mile (sec-mph):    
Braking (mph/ft)   
Top Spd (mph)   
Off Road Capability   Approach angle: 27 deg, Ground clearance (min): 196mm (7.7"), Departure angle: 28 deg, Ramp breakover angle: 24 deg, Ground clearance (max): 196mm (7.7")
Options:  

Convenience Package -- Laramie models add leather upholstery, dual-zone climate control, steering-wheel-mounted audio controls, heated front seats, security alarm, auto-dimming rearview mirror, chrome moldings and Sentry Key engine immobilizer, etc.... all but navigation or sunroof.


Dodge Ram Replacement bulb sizes

2008 Dodge Ram bulb replacements Replacement bulbs:
High & low beam headlamp hallogen H13
Front Turn Signal 3157NAK
Cab Clearance Lights   168/194
Cab Clearance Replacements   Full Replacements: Clear, Smoke or Ion.
Dual Rear Wheels Side   168/194 White, Front Side Amber and Rear Red
DRW Side Replacements   Full Replacements: Clear, Smoke or Ion.
Dual Rear Wheels Tailgate   168/194
Tail light   3057
Rear Turn Signal   3057
Center Stop light   912 same as a 168/194 or replacement 920256
License plate   168/194
Back up light   3057
Sidemarker   W5W same as a 168/194
Rear Cargo Light   912 same as a 168/194
Fog Lamp   9006LL Yellow, but other colors available
Overhead Console   TS 212-2
Dome Light   7679

 


(More to be added once available):

    2010
  • SEMA Show - Las Vegas, NV - Oct 29th-Nov 6th as Tow Vehicle
  • 6th Annual Lonestar Toyota Jamboree - BMRA - Jan 13-16th as Tow Vehicle

 


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