I will be adding common questions to the top of this faq as they come up... PM me if I miss something or you think something needs to be added...

Check this out... picture resizing tool found here... www.irfanview.com use this all the time and it works great!
another great resizing tool
http://download.microsoft.com/downlo...ertoySetup.exe

Wiring Problem spots
https://dodgeforum.com/m_1132109/tm.htm

information on the 53 block problem
http://www.stamey.info/Truck/Cummins...NewInformation

Information on the 53 block cracking problem...
http://www.stamey.info/Truck/Cummins...NewInformation

Performance Review Template:
https://dodgeforum.com/m_1123712/tm.htm

Performance Reviews: (at the bottom)
1) Performance Review: Quadzilla XZT
2) Performance Review: ATS intake vs Stock
3) Performance Review: Quadzilla Pulse PM



DIY writeups:
1. FSM link (Manuals)
2. Drews Brew
3. VP44 Injection pump info (TBD)
4. Silencer Ring removal
5. Differential servicing
6. Front wheel bearing servicing 2500/3500's
7. Oil bypass install (2 of them)
8. BHAF filter install
9. Ujoint lube tread
10. Rear mini leaf pack install
11. Power Steering Service DIY
12. NV5600 Teardown
13. DIY Fuel Filter
14. Pillar Gauge install
15. Drews Brew explained
16. Other 3rd Gen DIY writeups (mostly non CTD related)
17. DIY Towing mirror install
18. Front spacer/spring install
19. Death Wobble Thread... worth reading.
20. Valve Adjustment, 24V CR
21. Kore/Lorenz/Carli Suspension Comparison
22. Getting your Build Sheet DIY
23. B&M Shifter install
24. AFE Filter cleaning
25. DIY Brake Controller & Trailer Wire Install
26. 46re manual
27. DIY brake install
28. DIY 12v t-stat install
29. Transmission Temp Sensor lines.
30. DIY Alloy wheel restore
31. DIY shift **** swap
32. Quick Drain Valve from Fumoto Engineering
33. DIY Oil Change
34. DIY Tracbar install
35. DIY Toe alignment
36. DIY Fuel Tank Vent relocation
37. DIY Sub Install
38. PDFs of multiple years/parts
39. DIY steering shaft brace install
40. DIY Modified Block Heater cord
41. DIY ATS exhaust manifold install
42. DIY Cruise control switch R&R
43. DIY Tow mirror light install
44. 2004 owners manual
45. DIY Ball Joint Replacement
46. DIY Steering box install
47. DIY Heater Control Bulb Replacement
48. DIY Syntec Hub conversion







DIY Writeups
1. Merry Christmas thread... fsm's
https://dodgeforum.com/m_481983/tm.htm
https://dodgeforum.com/m_340929/tm.htm (2nd gen)
http://www.onlinefreeebooks.net/auto...anual-pdf.html

http://www.onlinefreeebooks.net/auto...anual-pdf.html


2. Drews Brew, what is it?
https://dodgeforum.com/forum/dodge-c...cal-yokel.html

3. VP44 Injection pump... (Drew, can you add your input here?... feel free to edit this post with whatever needs to be added)

4. silencer ring removal... read this thread
https://dodgeforum.com/forum/dodge-cummins-diesel/77946-silencer-ring-removal-cummins-diesel-ram-by-local-yokel.html

5. Diff servicing thread...
https://dodgeforum.com/m_652194/tm.htm

6. front 2500/3500 wheel bearing repack thread
https://dodgeforum.com/m_640907/tm.htm

7. Oil bypass install thread
https://dodgeforum.com/m_653443/tm.htm (Steves install)
https://dodgeforum.com/m_908536/tm.htm(Drews install)

8. BHAF install thread
https://dodgeforum.com/m_372134/tm.htm

9. front ujoint lube tread
https://dodgeforum.com/m_487238/tm.htm

10. Rear mini leaf pack install
https://dodgeforum.com/m_842685/tm.htm

11. Power Steering service
https://dodgeforum.com/m_856966/tm.htm

12. NV5600 Teardown
https://dodgeforum.com/m_864365/tm.htm

13. DIY Fuel Filter


14. Pillar Gauge install
https://dodgeforum.com/m_875603/tm.htm

15. Drews Brew
https://dodgeforum.com/m_578939/tm.htm

16. Other 3rd Gen DIY writeups (mostly non CTD related)
https://dodgeforum.com/m_685956/tm.htm

17. Towing Mirror install
https://dodgeforum.com/m_892300/tm.htm
https://dodgeforum.com/m_1183236/tm.htm

18. front spring/spacer install
https://dodgeforum.com/m_901296/tm.htm

19. Death Wobble thread
https://dodgeforum.com/m_901227/tm.htm

20. Valve Adjustment 24 Valve CR
https://dodgeforum.com/m_910497/tm.htm

21. Kore/Lorenz/Carli Suspension Comparison
https://dodgeforum.com/m_919574/tm.htm

22. Getting your Build Sheet DIY
https://dodgeforum.com/m_922730/tm.htm

23. B&M Shifter install
https://dodgeforum.com/m_910684/tm.htm

24. AFE Filter cleaning
https://dodgeforum.com/m_946650/tm.htm

25. DIY Brake Controller & Trailer Wire Install
https://dodgeforum.com/m_949158/tm.htm

26. 46re manual
http://www.scribd.com/doc/228727/Dod...Service-Manual

27. DIY brake install
https://dodgeforum.com/m_959389/tm.htm

28. DIY 12v t-stat install
https://dodgeforum.com/m_961443/tm.htm

29. Transmission Temp Sensor lines.
For the 2nd Gen http://www.dieselmanor.com/dm_products/DM-CLG2.asp
For the 3rd Gen http://www.dieselmanor.com/dm_products/DM-CLG3.asp

30. DIY Alloy wheel restore
https://dodgeforum.com/m_1005474/tm.htm

31. DIY shift **** swap
https://dodgeforum.com/m_837217/mpag.../tm.htm#837217

32. Quick Drain Valve from Fumoto Engineering
http://www.fumotousa.com/

33. DIY Oil Change
https://dodgeforum.com/m_725240/tm.htm

34. DIY Tracbar install
https://dodgeforum.com/m_1040856/tm.htm

35. DIY Toe alignment
https://dodgeforum.com/m_1040882/tm.htm

36. DIY Fuel Tank Vent relocation
https://dodgeforum.com/m_1098114/tm.htm

37. DIY Sub Install
https://dodgeforum.com/m_1098300/mpage_1/key_/tm.htm#1098300

38. PDFs of multiple years/parts
http://www.jameskowalski.com/Dodge/Parts/index.html

39. DIY steering shaft brace install
https://dodgeforum.com/m_1127046/tm.htm

40. DIY Modified Block Heater cord
https://dodgeforum.com/m_1233466/tm.htm

41. DIY ATS exhaust manifold install
https://dodgeforum.com/m_1340310/tm.htm

42. DIY Cruise control switch R&R
https://dodgeforum.com/forum/2nd-gen-ram-tech/171504-cruise-control-switch-r-and-r.html

43. DIY Tow mirror light install
https://dodgeforum.com/forum/dodge-ram-diesel-tech/148241-diy-tow-mirror-light-flasher-install.html

44. 2004 owners manual
http://oskin.ru/chrysler-dodge/manua...Ram_Diesel.pdf

45. DIY Ball Joint Replacement
https://dodgeforum.com/forum/dodge-c...placement.html

46. DIY Steering box install
https://dodgeforum.com/forum/dodge-c...ml#post1773776

47. DIY Heater Control Bulb Replacement
https://dodgeforum.com/forum/dodge-c...ml#post1860495

48. DIY Syntec Hub conversion
https://dodgeforum.com/forum/dodge-c...ml#post2191868






Performance Reviews
1) Performance Review: Quadzilla XZT
https://dodgeforum.com/m_1124545/tm.htm

2) Performance Review: ATS intake vs Stock
https://dodgeforum.com/m_1144857/tm.htm

3) Performance Review: Quadzilla Pulse PM
https://dodgeforum.com/m_1364369/tm.htm

 

here are the injector pumps with the year they were installed

89-94 Bosch VE Distributer pump
94-98.4 Bosch P7100 pump (AKA The Million Mile Pump)
98.5-02 Bosch VP44 Distributer pump, will go into more depth in a bit
03-07.4 CP3 (V. 1.3)
07.5 (6.7L) CP3 (V 3.1 I think)

the current CP3 pump for the 5.9's is capable of a max of 26,000 psi and the computer fires the injectors three times per injection event. the new 6.7L with the upgraded CP3 flows more fuel, at a slightly higher pressure, and the computer also fires the injectors 5 times per injector event.

I dont know much about VE pump. I know it has some adjustment screws on the back so you can play with the fueling advance and the AFC advance as well. this pump could dump some fuel, but not the like P7100.

the P7100 pump is quite possably the best fuel pump these engines ever had. it was dependable, easily rebuildable if needed, very stout, very easy to turn the power up on and can dump enough fuel to power over 800hp on #2 only. What made the pump so good was it was lubricated by the engine oil. the only problem these pumps ever had was when the switch from high sulfur to low sulfur caused some of the seals to dry out and leak. this was an easy fix and most were back on the road in only a day.

The VP44 pump has a similar distributer design as the VE pump, is the first electronic pump for the eingine giving the possability of timeing advance. the pump can power the same as the P7100 pump, however, you need electronics gagets to turn it up. Now we got the the main down fall of the pump, the Carter lift pump. The lift pump has a rather cheezy design that causes it to die prematurely, the origional design of the pump was to push fuel to the injector pump, not for doing a dual purpose of pulling from the tank and pushing that to the pump. The VP44 pump was lubricated and cooled by the diesel fuel itself, if you maintained a good flow of fuel to the VP44 there realy is not an issue, however if you started turning up the power, or the lift pump started going south the VP44 is being starved of fuel. This starvation of fuel and the lack of the lubricative properties of Diesel is what kills the pump. the internal Distributer would heat up, expand, and start eating away at the sealing surfaces causing low output pressure to even the pump welding itself together from excessive heat. The VE, P7100 and CP3 do not need Diesel for lubrication and are a good bit more robust if they are starved of fuel. This excessive friction from the lack of lubrication is where addatives come in handy, it keeps some lubrication in the pump so if the lift pump does happen to die it wont kill the VP44. From these Lift pumps dying also generated a market for aftermarket pusher pumps like the FASS pump and the walbro pump. there are others, but these are the most popular. Some people have gone as far as to re design the fueling system and actualy mount a P7100 pump to the 24 valve head just so the VP44 pump could be take out of the equasion.

in 05.5 the factory lift pump was moved from being mounted on the fuel filter to being put into the fuel tank. this has solved quite a few problems, however DC is still useing the same Carter pump. if the pump dies instead of just yanking the dead one off, the fuel tank has to be dropped. this equals more time in the shop.

More on the CP3 and the High Pressure Common Rail. in the past to bleed off injector lines to get the engine to run, you would crack the injector lines in the head and turn the engine over a few times to push the air out. this can also be done on the VP44 pump. however with the introduction of the HPCR you no longer need to do this. The pump and rail have been designed to automaticaly bleed the air out of the fuel lines. this means if you crack one of the lines on the head the engine will die if it is running. on the older pumps the engine would still run, it would skip but remain running. by cracking an injector line on the HPCR you are basicaly bleeding off the pressure generated by the CP3 to the rail, the injectors may be trying to fire, but there is no fuel pressure to fuel the cylinders any more. Cracking an injector lin on a HPCR is also VERY dangerous. the fuel is pressureized anywhere between 5000psi at idle to upwards of 26,000psi under load.

I hope this helps out a bit on the inner workings of the fuel systems of each year.

 

alright guys, in an attempt to clean things up a bit and not have so much pinned to the top we are adding hot links to the possable FAQ's and other stuff ya'll might want to know.

https://dodgeforum.com/m_771515/tm.htmFront and Rear Diff servicing for 3rd gens

http://www.cowboyplayground.com/public/dp.htmCowboy Bob's fuel pump install

https://dodgeforum.com/m_984315/tm.htm<= the complete list of trouble codes for 2nd gen 24 valves and all 3rd gens.

Thread with a good CEL/MIL codes database

Thread for Cummins QuickServe

Steve's x-mas thread for tech manuals

Thread about the 05 and later grease fitting

lesimon's thread about repacking the front bearings on his 3rd gen 4x4 w/detailed pics

https://dodgeforum.com/m_710666/tm.htm<= member Cumminalong (Rich) write up on drilling and tapping for an EGT sensor.

http://www.sabersix.com/images/DriveBelt-5.9_Diesel.pdf<= serpentine belt routing diagram brought to you by sabersix. . .THANKS BRO!!!

https://dodgeforum.com/m_873481/tm.htmgood link for wireing diagrams for just about every vehicle.

https://dodgeforum.com/m_1008799/tm.htm VP44 install videos.

https://dodgeforum.com/m_1128015/tm.htm Member Mayfair playing where's waldo with the oil pressure sending unit.

 

I have a question, don't know if it is an FAQ or not....

what is the max towing capacity of the '96 to '98.4 2500 CTD? How does that compare to later models?

 

Any exhaust options that wont void the warranty???

 

Drew,
So my '06 has the CP3 fuel pump, Would the FASS system be a good investment? How would it effect the manufacturer DC warranty?

 

Sonny, any exhaust yuou put on will only void the warranty of the exhaust, not the whole truck. however I would go to your dealership and talk with the service writer and get more information.

Jack, your 06 has a tank mounted fuel pump. the FASS pump has a much higher capacity then the stock carter pump thus undue stress of the FASS pump would be present since it would be haveing to draw through the stock pump. however you can get a kit to remove the stock pump, but this involves removal of the tank.

is the FASS better than the stocker. . .you bet. how would it effect the warranty. . .well, the dealership would have to prove the FASS system is what caused the problem. now, if you talk with your dealership you may be able to get them to install it depending on how you ask the service writer

 

Thanks for the info Drew , I also put in a new fuel /water separator FS19579. Piece of cake to do after following your pic's and info.

 

I'm new to the forum but can someone tell me what does remove the silencer ring on the turbo do and how does it help??

 

All the silencer ring does is make the turbo quieter. Taking it out requires a screwdriver to pry it out with.