It's been awhile since I've done much to the truck, and I think now's the time to add some more power. I don't want to go too insane, as the truck is mainly used to haul around a 7,000 lb camping trailer and for work around the house, but it'd be nice to have some more power for towing in the hills, and, of course, to have some fun. I also don't want to break the bank or have the truck down for an extended period of time.


Right now the truck has the following mods:

• Tymar Intake
• Hypermax 3" x 3.5" Downpipe
• Tymar Cat Delete
• Valair SMF & LuK Organic Clutch Kit

I'm considering the following mods, and was hoping to get some feedback on which ones will be the best bang for the buck:

• Gauges - These are probably first priority before any additional mods. I'm thinking a 3-gauge pod would be nice with EGT, boost, and what else? Where's the best place to pick up a gauge pod and gauges for our trucks?
• Chip - Any preferences?
• Exhaust - Everything from the cat delete pipe back is currently stock, so would I notice any benefits from upgrading? If I upgrade, I would want sound levels as close to stock as possible.
• Stage 1 Injectors - The truck has 160K on it, so my guess is the injectors could use some attention. If I'm going to rebuild them, I'm thinking I might want to go to Stage 1 instead of rebuilding to OEM specs?
• HPOP - Not sure if this would need any attention given the relatively minor mods I am planning, but I certainly want to make sure I can properly fuel the upgraded injectors.

Before investing in any upgrades, I'd want to make sure the truck is in good mechanical shape. Anything I should look at in particular? The truck runs fantastic right now (knocking on wood). I do get a very minor amount of smoke at idle once in awhile (I'm thinking injector o-rings), especially when the truck is cold, and it does tend to smoke a little when pushing it hard up a grade. It smokes like a chimney at higher elevations after sitting a day or two when it's cooler out until I start driving it, but, from what I've read, this all sounds pretty normal. The most I ever burn between 5K oil changes is 2 quarts, and that's only if most of those miles have been with the truck hooked up to heavy loads. I have gone a full 5K with no heavy loads on the truck without burning any oil.

I'd love to have unlimited resources and upgrade the turbo and install an intercooler, but I think I'll save those ideas for if and when the turbo gives out. I haven't ever pulled the intake boot to inspect the turbo, but it spools up great and I have ZERO oil leaks. In fact, the entire truck doesn't leak a drop, which is more than I can say about my Taurus SHO!

As always, thanks a million for any input and/or advice!

 

Alright, Gauges are a must before you start modding any further. I have Autometer ultra lites and i like them but you can also get Isspro which are pretty nice quality. Since you have a manual, you dont need tranny temp, which would mean you could just do a 2 gauge pod but if you want another gauge and a 3 gauge pod. I would strongly suggest a scan gauge... You can read codes with it, do a buzz test, cct, and it reads things like pulse width, injector duty cycle, oil temp.... Everything. I'm hoping to get one soon. Also, for your exhaust, i would look into a cat back system since you already have the dowpipe. Cat back will hook up to your downpipe. If you want it to sound close to stock, get yourself a 4" system with a muffler, It will be slightly louder but the muffler will help it stay very mild and toned. For a chip, you will want to get a custom tuned chip from any of the custom tuners which include but aren't limited to...PHP, Tony Wildman, Swamps, Beans, Gearhead, DP.... and many more. Pick your poison! With 160k miles, your injectors are probably still alright and would definitely be a great core to upgrade to stage 1 injectors. Look at Rosewood diesel and maybe give them a call. It's fairly inexpensive to get them rebuilt especially since your injectors have relatively low miles on them. As for the HPOP, you can upgrade to a 17* pump out of a superduty since yours is a 96 model. That would certainly help. I wouldn't really worry about it too much as of now. Again, your truck is a relatively low miled truck and your 15* pump should be in pretty good condition. You can always upgrade later down the road.

 

If you do much towing you will want to look into the intercooler sooner than later if you put in the bigger injectors. James is right on but I'd look into the hpop upgrade as soon as possible too. The stock 15 won't supply enough oil to fully use the injector/chip combo to their potential.

 

You're on the right track and agree with the above posts about getting gauges next. I have the Isspro EV2's and like them very much. The are led back-lit and match the factory dash gauges perfectly. If you're going to do the 3 gauge pillar mount, you might consider putting a scan gauge in the 3rd hole. I've heard they are in short supply right now, but it's something you could always add later.
And if you decide to upgrade to a 17* HPOP, let me know. I bought one a while back and am looking to go with the new SRP1 instead.

 

Thanks guys for the input so far! I've spent the past week doing quite a bit of research on the mods I want to do and considering the suggestions you all made. It sounds as though I should seriously consider an intercooler before upgrading to Stage 1 injectors since the truck is mainly used for towing.

Since I don't want to break the bank on this round of mods and I currently don't have any problems with my injectors, fuel pump, HPOP, or glow plugs, I'm thinking I might put off the injectors until later and focus on supporting mods, such as gauges, a chip, and exhaust. I'm guessing these three mods willl run me right around $1,500, which is a lot better than $3K+ if I upgraded the injectors, HPOP, and added an intercooler at the same time.

For gauges, I'm leaning towards a 3-gauge pillar mount with a Isspro EV2 pyro and boost gauge. I'm thinking DP-Tuner for the chip with a gauge switcher to fill the third hole in the pillar mount. I'm not sure yet on the exhaust, as I haven't found a place that sells just a 4" cat-back system for our trucks.

What kind of power do you guys think I can expect once I add the exhaust and chip to my current mods?

Hopefully over the next year I can round up the parts to install an intercooler and then focus on upgrading the injectors next winter.

Thanks again!

 

50 to 80 HP max

 

What Mike Said... You should expect about 60 hp with exhaust and chip. Your injectors will hold you back because you only have 90cc worth of fuel to use. So even though you get a chip with 140 hp tune, you wont get all of that. And for exhaust, chip and gauges, you should expect to pay about 1100. 300 for exhaust, 300 for gauges with pod, 500 for chip. Keep shopping if you can't get your prices around there.

 

You can get Sunpro gauges for under 200

 

I forgot you want a scan gauge. Thats 250... So looking at about 400 for gauges with pod.

 

Rosewood has the PHP chip for $350
Sunpro Diesel Gauge kit $200
Glowshift pod $30
Exhaust $300 ish depending on where you get it or who you know.

$900 and you'll have a good reliable setup.