2007 Ram 3500 build thread

skyking

Lifer
Nov 21, 2001
22,386
5,360
146
Rather than continuing to spam the wrenching thread, I will post up here.
This is the truck as I purchased it.


Since then I have done little externally, just some nerf bars and removed those 34"s for stock rims and tires.
The 34"s go back on Sunday because they have better snow traction.
My friend is well versed in overhauling differentials, so I opted to change the 3.73 final drive for the 3.42 gearing in later trucks. I also added free spin locking hubs to get rid of all that turning mass up front, and replaced the steering with the latest iteration of Dodge stock parts.
The free spin hubs are also for trailer work. I can select 4wd low, but with the hubs locked out I get 2wd low.
This is hugely beneficial for backing a heavy trailer up a hill around a corner into a tight spot. Even with the 3.73 gears I would be slipping the clutch a little, and now I put it in low, take my foot off the clutch and it can push a trailer up a tree at idle.
I knew it burned oil when I got it, and was hoping to get to next winter. It was on borrowed time and Murphy foreclosed on the loan
I went out to go run an errand early last month and it ran like crap, smoking and loping like it was running on 5.

I had already purchased a new clutch, and I ran up to my friend's place the following Monday and had the engine in the back of his truck by Tuesday noon.
I took it to a trusted builder in Canada, and this guy pulled out all the stops for me. he had it apart that night and found the broken top rings on two cylinders, took the block to one machine shop and the head to another. He had it done complete with .020 over Moly pistons, new seats and guides in the head, inspected and new bearings throughout by the next Tuesday! It was more like a NASCAR pit stop than a typical 1 month long build cycle.
I found metal in my manual transmission ( thank you again Mr Murphy) so I opted for a later model G56 with taller gearing. Now granny is the norm for launching, where 2nd used to be.
The engine is stock with the exception of a Colt Big Stick stage 3 camshaft.
http://www.coltcams.com/html/cummins_5_9_camshafts/
 
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skyking

Lifer
Nov 21, 2001
22,386
5,360
146
Note the almost complete radiator block. IAT was about 65, with almost the entire CAC and radiator covered.
 
Last edited:

jlee

Lifer
Sep 12, 2001
48,518
223
106
I don't need a turbodiesel, I don't need a turbodiesel, I don't need a turbodiesel, I don't need a turbodiesel, I don't need a turbodiesel, I don't need a turbodiesel.......

Complete rebuild in a week? That's impressive!
 
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skyking

Lifer
Nov 21, 2001
22,386
5,360
146
da, torques.
I did not get a dual disk clutch, must limit my torques to less than 900........
I've never had a real 4WD, and this snow is quite fun with it.
 
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skyking

Lifer
Nov 21, 2001
22,386
5,360
146
Tried to get some decent MPG's on the way home but it was not to be. temps were around 5 F, and then I had to put my boot in it to get my brother to his train on time. I had blocked the most of the CAC and radiator with a rudimentary application of recycled political signage, but it was not enough. All I got in cruise was about a 30 F rise.
I could boot it as hard as I wanted to and the engine driven fan never ran. I need to really seal things off in the winter up there!
 

JCH13

Diamond Member
Sep 14, 2010
4,981
66
91
Could the thermostat be stuck open? Or is this just how big diesel engines are?
 

skyking

Lifer
Nov 21, 2001
22,386
5,360
146
The coolant temps were approaching the T-stat level OK. There is no such thing for the CAC air. Cooler air = more power capability, but cooler air = less MPG. The engine is a heat machine and it works more efficiently at warmer temps. I will be making some custom wraps for the CAC that I can easily open up when needed for towing.
I don't intend to daily drive a big truck when I have a 46 MPG Beetle, but I will do what I can do (cheaply) to help the truck out.
The dilemma is this: The truck was designed to tow 17000 pounds up over the highest pass, In Summer, without overheating. Worst case scenario engineering.
They did well with the electrically controlled fan clutch; when it does come on it sounds like a Blackhawk helicopter got under the hood. Very low loads when it is off and able to chill it out when needed. I think the number I read was 27 hp to drive the fan at full go!
I tow 8500 pounds at most. I can do some work to reduce cooling air drag and raise up the temps, with easily removable sections if it gets too warm. I have a combination tuner and gauge set that will give me everything the OBDII puts out,and just got a splitter and Bluetooth so I can run Torque pro or something similar.
 
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DaTT

Garage Moderator
Moderator
Feb 13, 2003
13,295
118
106
I love big diesel torque monsters. Nice buy!
 

skyking

Lifer
Nov 21, 2001
22,386
5,360
146
It was just a tad dicey on the way over. Even with a very tender foot, black ice plus some slow and go and no weight in the back = a little fishtail that was unwanted. lever was pulled back into 4wd and that cured that.
 

skyking

Lifer
Nov 21, 2001
22,386
5,360
146
I got in a decent test run today. The engine is at 1300 miles. I ran up and back through the Seattle area, 170 mile loop at ~60 MPH. It did 23.4 MPG with the ~34" Nitto Grapplers. Next I will put some stock sized Michelin highway tires on.
 

skyking

Lifer
Nov 21, 2001
22,386
5,360
146
So I made another run across the mountains to do some work. Stock steelies and Michelin LTX A/S highway tread, weighed in at 84 pounds a unit.
Route was across some 1000' small hills, over White Pass @4500 feet, down to Yakima, up I-82 to I-90 and across Snoqualmie. Total of about 10,000 feet of climbs.
60 MPH up the hills and 65 down got me 23.55 MPG.
I scored some of the lightest wheels around, the stock alloys off the 2011 4th generation Ram. The same Michelins on those alloys is 61 pounds, for a total reduction of 92 pounds of rotating mass. I will report the results.
 

JCH13

Diamond Member
Sep 14, 2010
4,981
66
91
Good goddamn... I wish I could pull 92lbs of rotating mass out of my vehicles...

This giant diesel truck thing is a whole world heavier than anything I've ever owned, making your thread very interesting to me. Keep the updates coming!
 
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skyking

Lifer
Nov 21, 2001
22,386
5,360
146
I have a tentative 190 mile run tomorrow, down the relatively flat I-5 corridor. I plan on installing these new wheels today and get a good test in. Supposed to be dry conditions which makes a big difference. After that run I will build and install a front air dam and wait for another dry day and good reason to make a run.
I have some nice conveyor belt material. It won't hold shape without support, so i will support it at least midway and leave the bottom 6" free to allow for hits. It will be 9~10" or so above the ground. Plenty high for most things and I hope the last 6" being flexible will keep it on when I step off the pavement. With these highway tires, I can't do much out there anyway.
I sold the 99 pound Nittos and wheels for almost all the money I have in these light alloys. I will sell one of the stock wheel sets I have, and mount my new (used) studded snow tires I got the other day. I picked up a set in great shape for $250, and he gave me the chains that went with them.
 

skyking

Lifer
Nov 21, 2001
22,386
5,360
146
turned into a 320 mile trip. I had a ladder over the top of the tailgate, but I had the front of it elevated so it was not a total aero mess. LOL, the truck has a CD of .52, who am I kidding
To keep things equal I pinned it at 60, other than the 40 miles of city and country driving at the various destinations.
24.27 MPG, the best so far. This is the baseline for any future mods.
When I got the truck it was stuck at 19. Regearing it took it to 22. New cam and a little higher OD ratio got it to here.
 
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