I have a 2002 1500 4x4 with 220,000K+ miles that I am wanting to rebuild with my son and want to up the power to use it for pulling a camper if needed. We will be stripping the block bare and sending to machine shop along with heads for inspection (maybe bored, milled and heads port polished?). Replacing the obvious parts, timing chain, oil pump.... I plan on having the transmission rebuilt as well (clutch kit?) Along with rebuilding the rear end (change gear ratio or swap to a Dana?). Im looking for the most bang for the buck. Im a mechanic, not a performance/upgrade guy so looking for some help. I dont want a 500 HP engine. Just something that is better than stock to aid in pulling the camper. Thanks!
Current state
Engine: 5.9L gas
Trans: 46RE
Rear Axle: Chrysler 9.25 with 3.55 gear

 

Check out some of the 408 build threads here.

I wouldn't bother with the stock heads, not at that mileage. They are prone to cracking, and yours very likely are. There are new casting stockers available, or, if you like, there are a selection of performance heads as well. Pick a combination that works for you.

The 46RE trans is reasonably reliable, if not abused..... but, if you want to make it even more stout, rumor has it, that 47, or even 48RE hard parts will fit in there perfectly.

What gears you run is going to depend on what size tires you want to run. If you are sticking with stock size tires, the 3.55's will be fine.

 

Sounds like a decent father/son project. Post pictures of your project as you progress. If you want some cheap bling, find a set of someone cheap take-off wheels off a new truck (five bolt rims). I found a set of a 2010 TRX 20in for $150, including decent rubber.

My son and I bought a 2001 dodge 1500 5.2L with a blown motor in it. Easy fix, I just found a decent replacement at a wrecker for $500. The truck didn't need much else and we have put 30-40k on the truck in the last few years.