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Download www.turbodieselregister.com TDR 61 INDEX Here it is summer
Transcript
INDEX Here it is summer again, and with it the annual TDR index, a guide to content of Issues 57 through 60. The TDR is unrivaled in its coverage of Turbo Diesel resources, and this index is designed to be an “engine” for ready access by imposing a rational order and analysis on such extensive coverage. Arranged alphabetically and chronologicaly, each entry includes not just the head word or phrase to identify the topic, but also a summary of information presented by TDR writers. We have taken our lead from Michel de Montaigne who four centuries ago famously admonished his readers that Abrasive Flow Machining (AFM). See Extrude honing Accelerator pedal position sensor (APPS), bad, cause of poor drivability Issue 60 (Have Ram, Will Travel) Joe Donnelly observes that complaints identified as poor drivability and misdiagnosed as failing injectors can in fact be traced to a bad accelerator pedal position sensor. 92 Accessories, added by the editor to his new Mega Cab Issue 59 (Member2Member) From the myriad of accessories listed in Issue 58 by TDR writers as their favorites, the editor identifies the ones he has added to his ‘07.5 3500 Mega Cab, Long Bed truck, with thumbnail evaluations and brand names. 10–11 Accessories, ill-matched, useless or ill-considered. See also Coffee-Table Engineering, anecdotes and cautions Issue 57 (Four Whaling) G.R. Whale lists and describes ill-considered truck accessories, high-tech fopperies, and useless refinements which he observed on a recent road trip. 70–74 Accessories for power- and performance-enhancement Issue 58 (Member2Member) Joe Donnelly makes recommendations on where to start and how to proceed in accessorizing a new Turbo Diesel, including gauges, air intake system, transfer pump, torque converter, exhaust brake, suspension, and tires. 8 Accessories for the Turbo Diesel truck, favorites, surveyed by TDR staff writers. See also Topic headings of individual categories, parts or products, by generic or brand name Issue 58 (Tailgating) The editor, new owner of a scarcely-used truck, assigns TDR staff writers who have outfitted new Turbo Diesels since the last magazine roundup on accessories, to report on their favorites. 4 Issue 58 (Member2Member) Bill Stockard lists favorite accessories for a new truck, in three categories: “Specific Use,” “Must Have,” and “Preferred.” 10–11 Issue 58 (Idle Clatter) Jim Anderson itemizes accessories to his ‘06 3500 dually: spray-in bed liner, Pacbrake, 70-gallon fuel tank, steel steps, gauges, mud flaps, bed-mounted toolbox, and WigiDigit Gate Glide, all of which perform “as expected.” 60 Issue 58 (Four Whaling) After making broad comparisons between three new diesel pickups he tested for Diesel World magazine, Greg Whale identifies accessories he would add to a new Turbo Diesel with a 6.7-liter engine. 78–80 Issue 58 (Ranch Dressing) As assigned, John Holmes lists accessories he would add to any new Turbo Diesel: Mag-Hytec pans and covers, gauges, White Night rear lighting system, GateGlide, Slide-N-Lock, mud flaps, running boards, and boonie box. 104 Issue 58 (Polly’s Pickup) Polly Holmes lists accessories she most appreciates on her ‘03 Turbo Diesel, including GateGlide, Cold Air Box, Turbo Air Guide, Cool Hose, Muffler Elimination Kit, BD exhaust brake, and Mag-Hytec pans and covers. 108 Issue 58 (Life’s A Beach) Jerry Nielsen lists favorite accessories: Painless wiring setup, exhaust brake, gauges, Banks tuner and intercooler, FASS, Air Lift Suspension system, Kirby On Board Air, steps, SRT-10 hood scoop, and Mag-Hytec covers. 110–111 Issue 58 (Celebrity Corner) Confessing he has “gone over to the dark side,” Sam Memmolo maintains that “truck accessories are truck accessories” and enumerates an array of items he values as add-ons to any pickup truck. 112 Issue 58 (Back In The Saddle) Scott Dalgleish pens a ditty to the tune, “A Few of My Favorite Things” from “The Sound of Music,” to give us the rhyme, if not the reason, of accessories he is addicted to. 114 Issue 58 (Have Ram, Will Travel) Joe Donnelly lists two dozen accessories added to his ‘04 Turbo Diesel, as well as other add-ons for trucks in the series, distinguishing which are specific to particular model years, and provides sources. 120 Issue 58 (From The Shop Floor) Andy Redmond lists popular accessories in four categories: 12 exterior; 6 interior, 7 drivetrain/towing, with a special section on 4 highly useful auxiliary gauges. 147–149 Accessorizing, need for a plan Issue 58 (From The Shop Floor) Andy Redmond emphasizes importance of planning ahead when accessorizing a vehicle, to budget for unforeseen but necessary concurrent costs. 146 Accessory installation, in-cab, savvy advice for simplifying the job Issue 60 (6.7 HPCR) The editor shares some general assembly and disassembly tricks, shortcuts, and old-hand’s workarounds in dealing with fascia, door panels, dash, fire wall, and behind-the-scenes wiring. 40–43 54 www.turbodieselregister.com TDR 61 “We can be knowledgeable drawing on other men’s knowledge, but we cannot make wise use of that knowledge without following deliberate method and systematic analysis.” With Montaigne’s rule of method as a guide, we hope that you, sage TDR reader, will find this latest installment of the annual index to be serviceable, using it as a conscious tool for getting answers, solving problems, and better appreciating your Turbo Diesel. Bob and Jeannette Vallier TDR Writers/Editors Air-fuel Control Housing (AFC) pressure line, effect of diameter on boost changes Issue 58 (First Generation) Joe Donnelly explains variation in tube diameter in the AFC pressure line and its effect in dampening response to boost changes. 18 Air box, OEM vs. PSM sealed system. See Air intake systems, reviews Air compressor, on-board Issue 58 (From The Shop Floor) Andy Redmond remarks on the merits of installing an on-board air compressor and air tank for operating air-controlled accessories, and provides a picture of the Ride Rite unit mounted on the engine. 149 Air conditioner output efficiency, estimation of Issue 57 (5.9 HPCR) Cooling efficiency of the air conditioner is affected by ambient temperature and humidity, such that a typical cooling formula calculates the operating environment less 35-45°F. 42 Air delivery, compound grille-to-fender air dam and hoodscoop system Issue 58 (TDRelease) Member Scott Oudshoorn has designed and fabricated a compound air delivery system comprised of fiberglass air dam grille-to-fender inlet and a fully functional hoodscoop; he solicits interest from consumers and venture investors. 158–159 Air filter, constricted. See Boost pressure reading, low under load Air intake heat shield Issue 59 (24-Valve Engines) Joe Donnelly digests information on several brands of air filter systems with built-in heat shield; and offers general advice. 35 Air intake horn, for Third Generation 5.9 engines, aftermarket Issue 58 (Have Ram, Will Travel) Joe Donnelly tests the Blade Runner Charge Air Manifold by Advanced Flow Engineering on the dyno and on the road, and reports good results. 120–122 Air intake systems, reviews Issue 57 (Life’s A Beach) Employing a Superflow SF-1020 flow bench tester, Jerry Nielsen compares and evaluates the Banks, the aFe, and stock air-filtration systems. 110–111 Issue 57 (TDRelease) Advanced Flow Engineering introduces the VE-Force Charge Air Manifold for the ‘03-’07 Dodge-Cummins Turbo Diesel pickup, to improve air delivery to the engine. 160 Issue 59 (24-Valve Engines) Joe Donnelly tabulates results of his tests evaluating 11 air box filter products and configurations, reproduced from his exposition in Issue 37, pp. 26-27. 35 Issue 59 (Product Showcase) Pete Tomka continues researching air-intake systems, summarizes material presented in Issue 56; analyzes representative configurations for the detrimental effects of elevated temperature on power and EGT in road & dyno tests. 130–134 Air Lift air bags. See Suspension kits, aftermarket Aisin, corporate background Issue 59 (Blowin’ In The Wind) From the Wikipedia website, the editor abstracts information on Aisin, maker of the automatic transmission for the 3500/4500/5500 Cab and Chassis truck. 52 Alaska RV travel Issue 60 (TDRV) Nine RV trips to Alaska have given Dave and Millie Peach the experience to instruct in how to prepare, places to visit, rules of the road, rewards of the demanding adventure. 126–128 Alternator, troubleshooting Issue 58 (First Generation) Several TDR readers suggest causes and fixes of alternator problems manifested in “Check Engine” lights and malfunction of electrical accessories. 17 Anniversary, TDR 15 years Issue 60 (Tailgating) With the appearance of Issue 60, the TDR observes 15 years of publication, which the editor celebrates by announcing conversion to full-color printing. 4 Anti-theft switch, installation of Issue 59 (5.9 HPCR) A reader is instructed in how to discriminate among the various color-coded wires in the bundle from the key switch. 39 Antilock brake/speed sensor, defective, effect on instrument readings. See Speedometer, troubleshooting TDResource . . . . Continued Antilock brake warning light, erratic Issue 59 (First Generation) The weakness of the rear antilock brake system in First Generation trucks may lead to blown fuses and erratic ABS warning light, which can be “solved” by simply disconnecting the light switch, if braking is okay otherwise. 18 Appearance, accessorizing your rig for a meaner look Issue 60 (Ranch Dressing) John Holmes describes some heavy metal and chrome accessories to make your vehicle appear more macho. 74–75 ARP head studs Issue 59 (Back In The Saddle) Scott Dalgleish advises head studs when increasing boost above 50 psi, and describes installation of the ARP brand for optimum cylinder head-to-block sealing. 88–89 Automatic Transmission Fluid (ATF) Issue 58 (Ranch Dressing) John Holmes describes advances in formulation of automatic transmission fluids and specifies use of Mopar ATF+4, required in late model Turbo Diesels and backward compatible for earlier models. 106 Automatic transmission indicator, adjustment of Issue 58 (First Generation) A TDR member diagnoses ignition failure and misaligned automatic transmission indicator in a First Generation truck and provides information for repair. 18 Auto shows. See Barrett-Jackson antique auto auction; See North American International Auto Show (NAIAS) Axle, rear, Dana 80, backlash and preload specs Issue 58 (12-Valve Engines) In answer to a reader’s query, Joe Donnelly specifies his preferences in setting preload and backlash in the Dana 80. 24 Axle ratio, pulling efficiency of OEM 6.7 HPCR configuration Issue 58 (6.7 HPCR) A member road tests the 6.7 HPCR and finds he doesn’t need a 4.10 axle ratio for towing at maximum GCWR with the 68RFE transmission. 42–43 Backspace, in wheel measurement. See Wheel, measuring and calculating offset and backspace Backup light, failed, troubleshooting. See Backup light switch, repair of Backup light, Light Buster by Blazer. See Accessories, added by the editor to his new Mega Cab Backup light switch, repair of Issue 58 (12-Valve Engines) TDR members provide a guide to troubleshooting a failed backup light and instructions for locating, repairing and replacing the switch. 22 Backup sensor, Parking Partner. See Accessories, added by the editor to his new Mega Cab Badge engineering Issue 59 (Four Whaling) Greg Whale writes on the industry practice of “badge engineering,” i.e., building several differently-branded vehicles on the same platform to fill several marketing niches, with examples including Pontiac Solstice and Saturn Sky. 54–56 Barrett-Jackson antique auto auction Issue 60 (Polly’s Pickup) Polly Holmes spotlights the 2007 Barrett-Jackson antique auto auction, observing that attendance was down, suggesting a buyer’s market. 77 Batteries, information roundup Issue 59 (Ranch Dressing) John Holmes provides a veritable “Batteries 101” in an exposition on what you need to know when checking and replacing the pair of batteries in a Turbo Diesel pickup. 66 Batteries, recharging Issue 57 (5.9 HPCR) A reader whose battery died after he left the ignition turned on for a week gets an explanation and advice on proper recharging. 43 Batteries, troubleshooting. See Electrical problems, troubleshooting, tools, and fixes Battery cables, optional sources Issue 59 (12-Valve Engines) Readers compare notes on specs and sources, including marine or agricultural equipment dealers, for replacement battery cables. 26 BD brand Turbos, compound (“twin”). See Turbochargers, compound, advantages of Bed cap Issue 57 (Back In The Saddle) To provide a cab-high canopy over his truck bed, Scott Dalgleish selects a Leer model 100XL, and describes its specs, options, and advantages. 116 Issue 58 (Member2Member) The A.R.E. “Z” topper gets high marks from Doug Leno for its OEMlike style, and its electric lock wired to the truck’s security system. 13 Bed carpet Issue 58 (Member2Member) A pre-formed carpet called the BedRug permits Doug Leno to alternate using his truck bed between normal day-to-day use and heavy hauling. 13 Bed cover, Agri-Cover Lite Rider. See Accessories, added by the editor to his new Mega Cab Bed liner, drop-in, compatibility with a gooseneck trailer hitch Issue 58 (TDRV) To concerns expressed about compatibility of a drop-in bed liner with a gooseneck hitch, an experienced reader says the problem is not water accumulation, but chaffing of painted metal, and recommends a spray-in bed liner. 164 Bed liner, spray-in, aftermarket Issue 58 (Member2Member) After four years of heavy use, the Line-X spray-in bed liner has proved its value to Doug Leno. 13 Bed liner, spray-in, do-it-yourself Issue 60 (Member2Member) As a do-it-yourself lightweight spray-in bed liner, the editor selects U-POL undercoating product applied by air-gun; and rates the results as an alternative to the Rhino-type product. 12–13 Bed liner, Super Truck brand. See Accessories, added by the editor to his new Mega Cab Bed protectors Issue 58 (Member2Member) Doug Leno describes three accessories added to his truck bed for increased versatility: spray-in bed liner, carpet, and cap. 13 Bed step, at tailgate entry, aftermarket Issue 57 (TDRelease) Flying M Enterprises manufactures a hitch step distinctively fabricated of welded 5/8” chain, with models for any ride height. 163 Issue 60 (Ranch Dressing) John Holmes describes a tailgate bed-step for First and Second Generation trucks, made by “Convert-A-Ball,” one model for two-wheel-drive and another for four-wheel drive pickups, to which he gives his seal of approval. 71 Belt, serpentine, squeaking, chirping Issue 57 (5.9 HPCR) Persistent squeaking or chirping in the radiator fan belt assembly may be solved by replacing the alternator pulley or replacing the belt with the Goodyear Gatorback belt. 41 Billet fuel filter cap Issue 57 (24-Valve Engines) Joe Donnelly recommends the billet fuel filter cap, available at Geno’s, to provide added strength, used with his 45 psi FASS fuel lift pump; explains its fit; and describes his method of monitoring pressure. 36 Biodiesel, analysis of current picture Issue 60 (Backfire) Although biodiesel has great potential and Europe has used rapeseed and palm oil formulations with success, in America there are major problems in sourcing raw material, formulation, and quality control, according to John Martin. 139 Biodiesel fuel, Big Oil’s tax stratagems Issue 58 (Idle Clatter) Under a heading called “Biodiesel Shenanigans,” Jim Anderson exposes stratagems Big Oil uses to reap tax benefits in the federal biodiesel subsidy program. 61 Biodiesel use in 6.7L engines, caution on use of Issue 60 (6.7 HPCR) A TDR member advises a reader to exercise caution and to carefully evaluate warranty risks in using biodiesel fuel in the 6.7L engine. 44 Block 53, problematic 24-valve engine casting Issue 60 (12-Valve Engines) Joe Donnelly provides information on the infamous “53” engine block, a casting used in some Dodge-Cummins engines produced in 1998 and subject to cracking; he explains how to find the block number on the engine. 22 Issue 60 (From The Shop Floor) Andy Redmond shines some light on “block 53,” an engine casting in some late ‘98.5–’01 Turbo Diesel trucks, which have a history of cracking, and reviews an unorthodox fix, the Lock-N-Stitch bolt-on repair patch. 114–115 Boost Fooler, explanation, description, and installation Issue 60 (Back In The Saddle) For members seeking added power in the ‘04.5–’07 Turbo Diesel but electing not to use a tuner, Scott Dalgleish describes the function and easy installation of BD’s Boost Fooler, which permits higher boost levels. 88 Boost gauge, providing access site in 6.7-liter engine’s intake manifold Issue 58 (6.7 HPCR) Joe Donnelly notes that the 6.7-liter engine lacks a predrilled tapped port in the intake manifold for hooking up a boost gauge, but access is provided by “boost bolts” available from TST and Geno’s Garage. 43 Boost pressure reading, low under load Issue 57 (24-Valve Engines) Low boost pressure readings under a load in a ‘02 Turbo Diesel are traced to the air filter. 39 Brake, front, pad, replacement interval Issue 60 (5.9 HPCR) Joe Donnelly says that his front brake pads and rotors show virtually no signs of wear after 80,000 miles, but that he has a set of factory replacements on the shelf for when he needs them. 38 Brake, parking, cable-retaining clips, source of Issue 59 (First Generation) Readers are provided with sources of parking-brake cable-retaining clips for First Generation Turbo Diesels. 24 Brake and turn signal lights, troubleshooting Issue 57 (12-Valve Engines) A member gives tips for troubleshooting failed brake and turnsignal lights. 34 Brake fluid, specs and servicing Issue 60 (Ranch Dressing) John Holmes explains brake fluids, distinguishes between DOT 3 and DOT 4, reminds readers of the necessity of periodic change, and recommends replacement interval. 73 Brake light bulb, failure and problems in replacing Issue 59 (5.9 HPCR) Because of problems with melting plastic brake light bulb ends in some late model Turbo Diesels, brake lights fail individually, best addressed by replacing the light bar/receptacle rail as a unit. 37 Brake master cylinder reservoir, leaking Issue 60 (First Generation) Brake fluid leaking from under the lid of the master cylinder reservoir on First Generation trucks may be fixed by replacing the gasket at the top rim or turning it over, or by tightening the steel bail that secures closure. 18 Brakes, rear, dually, disc conversion kit Issue 58 (TDRelease) EGR annouces a rear disc brake conversion kit for ‘94–’05 Turbo Diesel pickups with dual rear wheels. 157 Bumper, front, winch Issue 58 (12-Valve Engines) For a good front winch bumper, Joe Donnelly points to his Reunel assembly, featured in Issue 51. 28 Bumpers, late model, removal, repair, re-installation Issue 60 (Member2Member) With detailed photographs to illustrate the process, Robert Patton provides instructions for removing, repairing minor damage to, and re-installing bumpers to late model Turbo Diesel pickups. 10–11 Cab air filter, Cab Fresh brand. See Accessories, added by the editor to his new Mega Cab Cab clearance light, site of water leak Issue 57 (5.9 HPCR) A poor quality gasket beneath the cab clearance lights has been identified as cause of water leak at the A-pillar cover and/or grab handles, the subject of a service bulletin directing replacement to solve the problem. 42 Cab interior and upholstery, limited color schemes available Issue 58 (Four Whaling) A survey of new model pickups reveals a narrow choice of color for the vehicle’s interior, in the Dodge only tan or gray; other brands permit a similarly narrow choice; the result is “boring,” says G.R. Whale. 74–76 CAFE standards, 2020 mandate. See Fuel efficiency, meeting the 2020 mandate of 35 mpg CAFE Calendar, annual TDR Issue 57 (Tailgating) The editor solicits photos of members’ trucks for the annual TDR wall calendar. 4 Cameron, Kevin, his book “Top Dead Center” Issue 60 (Exhaust Note) The editor announces availability of Kevin Cameron’s book “Top Dead Center,” for sale in the Geno’s Garage catalog, in a package with a free spiral-bound volume of offprints from ten years of his columns in TDR. 153 Cam specs and durability Issue 59 (12-Valve Engines) Joe Donnelly provides specs for the stock cam lift and duration for the 12-valve Turbo Diesel engine. 30 TDR 61 www.turbodieselregister.com 55 TDResource . . . . Continued Camshaft gear, replacing Issue 58 (First Generation) A member with a damaged camshaft gear in a First Generation truck with 300,000 miles is instructed by Joe Donnelly in disassembly, replacement, and reassembly. 18 Issue 59 (12-Valve Engines) Joe Donnelly provides part numbers, cost estimates, list of necessary tools, procedure and instructions for pulling and installing the camshaft as well as for replacing the gear case in the 12-valve Turbo Diesel engine. 32–33 Cerberus Capital Management. See Chrysler Group, operations under Cerberus Change-oil signal, EVIC, accuracy uncertain. See Oil change interval, as signaled by EVIC diagnostic code, evaluating usefulness of Charging system, troubleshooting Issue 59 (First Generation) Possible causes of failure of the engine electrical charging system are advanced by several members, including problems with the ECM, battery, defective cable splice, and loss of negative ground cable. 18 Check Engine Light (CEL), troubleshooting. See also Engine Control Unit (ECU), AW reflash instructions Issue 58 (First Generation) A TDR reader explains the process of clearing “Check Engine” lights in both early- and late-model Turbo Diesel trucks. 17 Chirp, squeak in dash area, troubleshooting. See Noise, squeaking in windshield mount Chrysler Group, operations under Cerberus. See also Nardelli, Bob; See also Press, Jim Issue 57 (Ranch Dressing) John Holmes celebrates Daimler’s sale of Chrysler to Cerberus, observing that the German-America marriage was between unequal and incompatible parties; and that the new regime opens the way to bigger and better things for Dodge. 102–103 Issue 58 (Ranch Dressing) John Holmes updates news on personnel changes at Chrysler under Cerberus, states who’s who, and notes negative takes on Nardelli. 104–105 Issue 59 (Blowin’ In The Wind) In the wake of a string of failed vehicle models, Bob Nardelli lives up to his reputation and cuts costs, jobs, failed models, according to media reports. 52 Issue 59 (Ranch Dressing) John Holmes reports news out of Chrysler management and shakeups throughout the organization as welcome evidence that Cerberus is moving fast and wisely to improve efficiency, service to dealers, and support to customers. 65 Issue 60 (Ranch Dressing) The fortunes of Chrysler, and therefore of Dodge, are looking up, says John Holmes, who surveys new hardnosed decisions to enforce contracts with suppliers and to eliminate several unattractive models, while adding some winners. 70 Climate control backlight bulbs, replacing Issue 60 (5.9 HPCR) Readers dissect the problem of removing the backlight bulbs in the climatecontrol module of the Third Generation truck, identify the bulb part number, and work out a procedure for completing the replacement. 39 Climate control knob Issue 60 (12-Valve Engines) The Dodge part number for both the upper and the lower climatecontrol knobs on 12-valve trucks is provided by a reader, as #4882482. 22 Clutch, custom Issue 58 (Have Ram, Will Travel) Joe Donnelly recommends South Bend Clutch to TDR readers who may need a special-application clutch or one custom built for vehicles other than the Turbo Diesel. 124–125. Clutch, slipping, troubleshooting. See also Grease, excessive, cause of clutch slipping Issue 59 (Member2Member) Doug Leno recounts troubleshooting and repairing a Con-FE clutch plagued by persistent slippage, performed at Dynomite Diesel Performance. 12–13. Issue 59 (Ranch Dressing) John Holmes lists a dozen things to look for during a clutch overhaul to correct a slipping disk. 66 Clutch pilot bushing vs. bearing, estimating life expectancy of Issue 58 (12-Valve Engines) Joe Donnelly compares the two and estimates that neither pilot bushing nor bearing can be expected to last more than 100,000 miles of normal use. 26 Clutch problems, troubleshooting Issue 59 (Idle Clatter) Noting that in general the life of the clutch and the throwout bearing is determined by frequency with which they are engaged, Jim Anderson reviews symptoms of impending failure, troubleshooting, and replacement of parts. 60 Clutch safety start switch, replacement Issue 59 (12-Valve Engines) Quirks in the engine startup cycle are traced to the clutch pedal safety start switch, with the Dodge part number and replacement instructions provided. 28 Coffee-Table Engineering, anecdotes and cautions. See also Accessories, ill-matched, useless or ill-considered; See also Power enhancement, adding multiple products; See also Theme for Issue 57 Issue 57 (Four Whaling) G.R. Whale ruminates on the many esoteric parts catalogs and miscellaneous specialty sources he has drawn on over the years. 68–70 Issue 57 (Idle Clatter) Jim Anderson offers advice for avoiding obvious and expensive pitfalls resulting from haphazard “Coffee-Table Engineering,” i.e., mismatched and inappropriate accessories and options. 76 Issue 57 (Life’s A Beach) Jerry Nielsen cautions that before launching a buying spree for accessories, upgrades, and gadgets advertised on the Web and miscellaneous catalogs, it is wise to consult with others, plan carefully, and budget prudently. 110 Issue 57 (Back In The Saddle) Scott Dalgleish offers constructive strategies for successful “Coffee Table Engineering”: identifying purposes and goals, prioritizing and sequencing purchases, with careful consideration of compatibility of components. 114 Issue 57 (From The Shop Floor) Taking his motif from the Johnny Cash song “One Piece at a Time,” Andy Redmond recites tales of “Coffee-Table Engineering” gone bad, to argue that amateurs should carefully reckon their skills before they start. 150 Issue 57 (Exhaust Note) With the axiom “An engine is a system, not a parts list,” Kevin Cameron warns against the lure of advertising, and argues the importance of informed deliberation when we modify the complex mechanical systems of our trucks. 168–169 Cold-weather diesel operation, advice Issue 59 (Member2Member) In response to a reader’s question on how well a fuel lift pump may be expected to operate in arctic-like weather conditions, Joe Donnelly explains that the entire fuel-delivery system is subject to the same danger of gelling. 16 Cold-weather engine starting, guide to Issue 59 (Idle Clatter) Jim Anderson explains the special demands in vehicle operation under conditions of extreme cold, with a practical guide to procedures in engine startup. 61 Cold weather startup problem. See Engine startup, failure at low temperatures 56 www.turbodieselregister.com TDR 61 Color: the TDR goes full color Issue 60 (Tailgating) The editor announces that in celebration of TDR’s fifteen years of publication, the magazine has gone to full-color printing. 4 Compound (“twin”) turbos, backpressure issue. See Turbochargers, compound, addressing the backpressure issue Controller Area Network (CAN) Bus System, explained Issue 59 (Ranch Dressing) There are not a lot of things you can do to a Turbo Diesel engine at home anymore, says John Holmes, who cites and explains the Controller Area Network (CAN) bus systems which oversee and regulate all 2006-and-later Ram engines. 70 Control modules, electronic on-board OEM. See Integrated Power Modules, function of Converter lock-up Mystery switch. See Mystery switch, “Check Engine” light Coolant leak, troubleshooting. See also Radiator cap seepage and noise at Issue 59 (5.9 HPCR) A reader who suspects a leak of transmission fluid is guided through troubleshooting to find that instead he has a leak of coolant. 38 Issue 59 (5.9 HPCR) A reader suspecting a coolant leak from inside the bell housing is instructed by Joe Donnelly to check the seals inside but also to check the nearby heater hose/pipe junction. 39 Coolant leak at engine block, troubleshooting Issue 57 (First Generation) A small coolant leak from a cold (but not from a hot) engine block may be of negligible importance, something not really requiring a fix, according to a knowledgeable reader. 26 Coolant reservoir bottles, servicing Issue 60 (24-Valve Engines) Readers compare notes on removing engine coolant reservoirs when servicing the radiator in 24-valve engines. 26 Coolant temperature thermostat, troubleshooting. See Engine coolant temperature, erratic overheating, troubleshooting Crankcase vent filter, servicing Issue 60 (Have Ram, Will Travel) The Third Generation Turbo Diesel has a crankcase vent filter which periodically should be checked for restriction and cleared, says Joe Donnelly, who gives instructions for the procedure. 92 Crankshaft Position Sensor (CPS), location on the engine block Issue 58 (24-Valve Engines) Readers identify location of the Crankshaft Postion Sensor on the engine block and note a common problem in replacing it. 32 Crankshaft rear main seal, suspected site of oil leak. See Oil leak, driver’s-side engine-wall, troubleshooting Cummins, Lyle, “Diesels for … Submarine,” book review of. See also Diesel engines in submarines, history of development Issue 59 (Blowin’ In The Wind) Bruce Armstrong reviews “Diesels for the First Stealth Weapons: Submarine Power 1902–1945” by Lyle Cummins. 53 Cummins, Lyle, book publications Issue 60 (Blowin’ In The Wind) Lyle Cummins expresses his appreciation of TDR’s publicity of his recent book publication, and the editor pledges his continued support of this elder statesman and historian of diesel’s development and fortunes. 56 Cummins performance uprate kits, certified by EPA Issue 60 (Technical Topics) The editor notes that unlike the performance products of some in the field, Cummins’ uprate kits are EPA certified. 50–51 Cummins Turbo Diesel engine, unique in the marketplace Issue 59 (Four Whaling) Although the unique distinction may be lost after Cummins introduces its new V-6 and V-8 diesel engines, Greg Whale says that the Dodge Ram Turbo Diesel is still the lone medium heavy-duty product in its market segment. 54 Cup holder, Geno’s Garage source. See Accessories, added by the editor to his new Mega Cab Customer Satisfaction Notifications Issue 58 (TDReSource) The TDR reviews “Customer Satisfaction Notifications” on issues with transmission cooler lines, powertrain control module connectors, roll-over valve vent hoses, front suspension coil springs. 101–102 Cylinder head, general service procedures when replacing Issue 60 (12-Valve Engines) Joe Donnelly advises that a valve job is a good idea when reinstalling the cylinder head; he notes that usually head bolts are reusable after careful inspection and cleaning; and he specifies the preferred replacement gasket. 21 Dashboard warning lights, troubleshooting. See also Brake and turn signal lights, troubleshooting; See also Check Engine lights, clearing and reprogramming Issue 58 (First Generation) TDR readers troubleshoot a failure of the dashboard “Check Engine” light and of power to accessories, corrected by replacing the alternator. 17 DDP 90 Horsepower fuel injectors, effect on mpg. See Fuel injectors, upgrade, result in lower mpg DDP injectors, installation Issue 59 (Back In The Saddle) In his ongoing quest for higher performance, Scott Dalgleish describes the DDP 90 horsepower injector nozzles, their installation at Dynomite Diesel Performance, and resulting increase in performance. 86–87 Demonstration truck, modified for ultimate power and speed Issue 60 (Life’s A Beach) Jerry Nielsen itemizes products and vendors of uprates, upgrades, accessories, and power accessories added and/or modified by Brad Ekstam in his quest to build the fastest Dodge Turbo Diesel pickup on the planet. 80–81 Detroit Locker, 37-spline axles, availability Issue 57 (24-Valve Engines) Joe Donnelly provides Websites for information on the 37-spline axle for a reader’s 2002 truck running the Dana 80 Detroit Locker. 36 Diesel electric hybrid Issue 60 (Product Showcase) John Bodenhamer, familiar to readers as a TDR fan fighting in Iraq, tells of his work as a graduate student with a crew developing a practical diesel electric hybrid in a competition organized by Argonne National Laboratory. 140–142 Diesel engines in submarines, history of development Issue 58 (Exhaust Note) In Germany’s pre-WWI rush for military technical supremacy, Rudolf Diesel’s engine played a significant role, particularly in powering the Kaiser’s submarines: Kevin Cameron presents the drama of its successful development. 168–169 Diesel fuel, accidental contamination Issue 57 (Idle Clatter) Six ounces of weed killer accidentally added to the fuel tank probably would not damage the Turbo Diesel engine, opines Jim Anderson, who advises further dilution with real diesel. 78 TDResource . . . . Continued Diesel fuel, coping with high prices Issue 57 (Idle Clatter) Jim Anderson decries the driving practices of those who complain about high prices of diesel: the key to relative fuel economy is driving slower and limiting miles driven. 80 Diesel fuel, high cost: rationale for, and rationalization of Issue 60 (Blowin’ In The Wind) Ken Freund attributes the high price of diesel to machinations of speculators and oil giants; which the editor balances with an excerpt from the media arguing intractable complexities of supply, production, and the market. 58 Issue 60 (Blowin’ In The Wind) The editor expresses impatience at the high price of diesel and its imbalance with the price of gasoline; but proceeds to enumerate the prevailing constraints of supply, production, and market which partially explain it. 58 Diesel fuel, inaccurate measurement at the pump Issue 57 (Idle Clatter) In vending diesel fuel, price is based on 135,000 BTU per gallon at 60 degrees F at the pump; but at any other temperature measurement and cost are inaccurate, a discrepancy which could be, but is not, addressed by the industry. 86–87 Issue 58 (Idle Clatter) Jim Anderson reveals the subterfuge used by Big Oil to cheat fuel consumers at the pump by failing to compensate for fuel expansion at higher temperatures than the benchmark standard of 60 degrees F, resulting in short measure. 61 Issue 59 (Idle Clatter) Jim Anderson updates reporting on inaccurate fuel measurement at the pump resulting from disparity of volume at temperatures in storage tank and at the pump, shorting the consumer’s energy units per dollar. 58 Diesel fuel, technology benefits over gasoline Issue 60 (Blowin’ In The Wind) In a TDR blog Ken Freund explicates a report by the Rand Corporation arguing that diesel technology has demonstrable advantages, to both individual consumers and to society at large, over biofuels and petroleum gasoline. 55–56 Diesel fuel injection system, history of development Issue 59 (Exhaust Note) Kevin Cameron recounts the stages through which the diesel fuel injection system advanced, from the earliest days plagued by problems of irregular injection, finally solved by the common-rail system and electromagnetic injection. 140–141 Diesel Particulate Filter (DPF) regeneration, problems with Issue 58 (Backfire) Responding to a reader reporting DPF regeneration problems with his 6.7liter Turbo Diesel, the editor acknowledges the issue, under intense study by Chrysler engineers, with a pledge of continuing investigative reporting by TDR. 153 Diesel powered vehicles, industry news Issue 57 (Four Whaling) G.R. Whale reports increasing presence of diesel-powered vehicles in a worldwide market, citing vehicles scheduled at Hyundai, Nissan, Audi, and Mahindra. 70 Differential cover, aftermarket. See Oil pan and differential covers, aftermarket upgrade to increase pulling efficiency Differential pinion bearings, re-installation Issue 59 (12-Valve Engines) Joe Donnelly offers advice and provides instructions for re-installation of pinion bearings, which in most Turbo Diesel trucks use a collapsible rather than a solid spacer, requiring care to avoid excessive bearing preload. 30 Differential pinion seal, replacing Issue 59 (12-Valve Engines) Joe Donnelly explains leaks at the pinion seal and gives instructions for changing the seal. 30 Differential pinion seal leak, more likely with synthetic lube Issue 59 (12-Valve Engines) Even a small leak at the differential pinion seal will become more pronounced after switching from mineral-based to synthetic lube, Joe Donnelly explains, and suggests Lubrication Engineers #607 lube available from Mag-Hytec. 30 Dodge Cummins truck models, various. See Turbo Diesel Dodge military vehicles, WWII and Korean vintage. See Midwest Military, antique military vehicle parts Dodge pickup, 1948–’53 B-series Issue 59 (Miscellaneous Ramblings) Don Bunn visits Vernon Steffens in Minnesota to see a 1953 one-ton Dodge B-series, final year model of this most highly sought-after vintage Dodge pickup, with historical context and anecdotal detail. 120–122 Dodge pickups, finding parts discontinued by manufacturer Issue 58 (Idle Clatter) For an older-model truck, to find parts no longer available through dealer channels, Jim Anderson suggests several strategies: finding generic parts, searching junk yards, and buying a duplicate truck to cannibalize. 62 Dodge Ram ‘08 4500/5500 Turbo Diesel. See Turbo Diesel ‘08 4500/5500, specs for hauling weights Dodge Ram, new 2009-model 1500 pickup Issue 59 (Truckin’ Through The Internet) Greg Whale spots a fugitive photo of the 2009 Dodge Ram on a Mopar webpage: he and several TDR old hands give opinions and speculate on the new model’s innards. 108–109 Issue 60 (Truckin’ Through The Internet) Steve St. Laurent reviews the ‘09 Dodge 1500 Ram, assesses its appearance, its performance with the two engines currently available, V6 or a V8 Hemi, to give the new model a generally favorable assessment. 120–123 Issue 60 (Truckin’ Through The Internet) G.R. Whale adds his incisive observations of the new Dodge 1500, reviewed at greater length in this issue by Steve St. Laurent and Andy Mikonis. 123 Issue 60 (Truckin’ Through The Internet) Going deeper than the advertising publicity, Andy Mikonis examines details of design and convenience in the ‘09 Ram 1500 of interest to experienced truck guys. 124–125 Dodge trucks, gas-powered personal-use and recreational models, history Issue 58 (Miscellaneous Ramblings) Don Bunn writes about the Warlock and Macho Power Wagon, the Ramcharger, Little Red Express, and the Tophand, personal-use and recreational trucks introduced by Dodge in the 1970s. 144–145 Door, failure to open Issue 57 (First Generation) Readers suggest repairs for door latches in First Generation trucks. 22 Door panels, removal. See Accessory installation, in-cab, savvy advice for simplifying the job Dowel pin problem Issue 57 (The Way We Were) Scott Kilby and Robert Patton provide a simpler fix for the “killer dowel problem” in 12-valve engines, described and illustrated. 64–67 Issue 58 (Letter Exchange) A reader describes his procedure for breaching the fan shroud to access the site of the “killer dowel pin.” 7 Issue 58 (12-Valve Engines) Joe Donnelly describes the TST kit as an economical and satisfactory method of addressing the “killer dowel pin,” which can fall out of the gear case in production B engines built prior to calendar year ‘99, and advises checking the torque on the five gear-case bolts while the cover is off. 28 Issue 58 (Have Ram, Will Travel) In revisiting the chronic “killer dowel pin” problem in 12-valve engines, Joe Donnelly emphasizes the wisdom of preventive repair and attention also to loose gear case bolts. 125 Downpipe. See Turbocharger downpipe, aftermarket, for Second Generation Turbo Diesels DPF. See Diesel Particulate Filter Drag racing, diesel-powered vehicles Issue 59 (Have Ram, Will Travel) Joe Donnelly reports increasing inclusion of diesel-powered pickup trucks by the National Hot Rod Association, demonstrated by their more frequent entries in bracket drag racing events and coverage in the NHRA periodical. 92–93 Drivability, poor, troubleshooting. See also Accelerator pedal position sensor (APPS), bad, cause of poor drivability; See also Fuel control actuator (FCA), cause of poor drivability Issue 60 (Have Ram, Will Travel) Joe Donnelly notes that service shops sometimes take an indiscriminate approach to “poor drivability,” just throwing one part after another at the perceived problem, reminding us of the TDR’s practical value to members. 92 Driveline vibration, troubleshooting. See U-joint wear, as cause of driveline vibration Dynamometer horsepower, record figures Issue 57 (Have Ram, Will Travel) Joe Donnelly cites figures attesting to best-yet record high dyno horsepower results at May Madness 2007. 124–126 Dynamometer testing, vehicle prep by operator Issue 58 (6.7 HPCR) To a query from an owner who has never dyno tested a Turbo Diesel Joe Donnelly explains that the only vehicle prep required of the operator prior to dyno test is to put it in neutral or direct drive. 44 Earn Your Stripes, license tag Issue 57 (Earn Your Stripes) TDR continues to offer color-lithographed license tags bearing the Super Bee cartoon character to proclaim their increased engine power, in increments of 100 hp, at cost of $4. 140 Issue 58 (Earn Your Stripes) The TDR offers a license tag bearing the Super-B character for owners to proclaim power upgrades, in increments of 100 hp; and lists names of recipients in current quarter. 141 Issue 59 (TDR/R/R) The editor promotes the TDR’s license-type plate bearing the Super-B cartoon character, lithographed in color, for Turbo Desel owners to proclaim their power upgrades, in increments of 100 hp, available at cost of $4. 109 Issue 60 (TDR/R/R) TDR continues to offer color-lithographed license-type tags bearing the Super Bee cartoon character to proclaim a truck’s increased engine power, in increments of 100 hp, at cost of $4; and lists those sent out in the current quarter. 112 ECU reprogrammer, aftermarket Issue 57 (Product Showcase) The Predator, Diablo Sport’s tunable performance module electronically reprograms the original ECU chip. 158–159 EGT, higher maximum in later-model engines Issue 58 (5.9 HPCR) Cummins has made changes in engines of later-model Turbo Diesels to tolerate higher permissible EGT, described by Joe Donnelly. 39 EGT, reduction of, with BD “twin” turbos Issue 60 (Member2Member) Joe Donnelly makes brief mention of the fact that the BD twin turbos installed on his truck will reduce highway and towing EGTs 100° to 400°. 13 Ekstam, Brad, his “White Lightning,” rebuilding and accessorizing of. See Demonstration truck, modified for ultimate power and speed Electrical circuit surge protector, RV application Issue 60 (TDRV) Readers review surge protectors made by Progressive Industries which provide both plug-in and integrally wired systems with automatic reset to detect voltages too high or too low, safeguarding all RV on-board electrical appliances. 129 Electrical problems, troubleshooting, tools, and fixes Issue 58 (Idle Clatter) Jim Anderson describes the Turbo Diesel’s electrical system, components liable to fail, tools for snooping out problems, and hands-on fixes, in a veritable do-ityourself manual. 65–72 Emissions controls, legal challenge to performance vendors Issue 60 (Technical Topics) Identifying the underlying conflict between values and goals of the EPA and proponents of performance enhancement, the editor explores legal hazards faced by diesel aftermarket vendors of power accessories and upgrades. 50–52 Engine block casting #53. See Block 53, problematic 24-valve engine casting Engine block heater, electric cord Issue 59 (5.9 HPCR) Readers are advised that 2004 and newer diesels come equipped with block heater and electric socket installed, requiring only connection to shore power. 37 Issue 59 (6.7 HPCR) Geno’s Garage is a ready source of an electrical cord for connection to the OEM block heater, which in 6.7-liter models is located on the passenger side of the engine. 40 Engine Control Module (ECM), proper service labeling of required reflash Issue 60 (6.7 HPCR) Owners of 6.7 HPCR vehicles express anxiety and uncertainty about whether dealer service technicians are properly attaching stickers to record corrective engine flashes performed in compliance with TSB/recalls. 46 Engine Control Unit (ECU), AW reflash instructions Issue 60 (6.7 HPCR) Readers exhange information on recent (spring ‘08) AW reflash to correct check engine light. 44 Engine coolant temperature, erratic overheating, troubleshooting Issue 60 (24-Valve Engines) Cause of heater failure and erratic fluctuations in engine coolant temperatures is traced to a disconnect in the hose to the overflow bottle. 28 Engine failure, troubleshooting. See also Fuel obstruction, troubleshooting; See also Startup problems, troubleshooting Issue 58 (12-Valve Engines) Fueling failure, with consequent engine problems, can be caused by a loose connection in the fuel supply line. 24 Engine fan clutch, troubleshooting Issue 59 (5.9 HPCR) Joe Donnelly says failure of the fan clutch on 5.9 HPCR engines is uncommon and suspects continuous heavy loading in hot weather, but also suggests checking alignments of pulley and hub bearings, fan balance. 39 TDR 61 www.turbodieselregister.com 57 TDResource . . . . Continued Engine ignition starter, troubleshooting Issue 60 (24-Valve Engines) Cause of a dead starter is traced to a failure of the starter solenoid fuse. 26 Engine lube oil, API CI-4 (superseded by CJ-4), availability Issue 57 (Idle Clatter) Only the new CJ-4 rated oil is now to be found on most shelves at the time Jim Anderson wrote this piece (summer ‘07), but CI-4 may still be available at some parts stores or direct from distributors. 78 Issue 58 (Technical Topics) The editor scouts local area for availability of API category CI-4 lube, notes increasing scarcity. 52–53 Issue 59 (Idle Clatter) Jim Anderson, who concurs in preferring the superseded API CI-4 engine oil for his truck, reports success in special ordering it in his locale, but advises likeminded readers to stock up before it is discontinued. 59 Issue 59 (Backfire) TDR members identify sources of API CI-4 lube oil, including availability in five-gallon buckets by Valvoline, and Mobil’s Delvac MX. 126 Engine lube oil, API CJ-4 or CI-4, use specific to models Issue 57 (Technical Topics) John Martin explains why the newest API oil rating, CJ-4, is mandatory for the new 6.7-liter engines, while the older CI-4 remains the best choice for engines before year ‘07.5. 60 Issue 57 (Idle Clatter) Oil with the new API rating of CJ-4 is mandatory in ‘07-and-later trucks, but for trucks manufactured earlier the better choice is CI-4 plus. 78 Engine lube oil, change interval Issue 57 (Technical Topics) Robert Patton used the Fleetguard CC2543 testing kit at change intervals of six-, ten-, and 20,000 miles, to settle on 15,000 miles, which happens to be the factory’s schedule A requirement. 61 Issue 57 (Idle Clatter) While Valvoline and other refiners specify extended drain intervals for some oils and for fleet operators, Jim Anderson advises against it unless regularly lab-tested. 78 Engine lube oil, confusion in labeling of API CJ-4 Issue 58 (Technical Topics) John Martin reveals the market mischief and deceptive labeling of diesel engine lube oils accompanying the superseding of API CI-4. 54 Engine lube oil, instructions for changing Issue 57 (Technical Topics) Andy Coyle, TDR Web Site Moderator, recounts steps in changing engine oil in the Turbo Diesel truck, interspersed with humorous asides and personal anecdotes, intended to instruct and entertain. 62 Engine lube oil, special label Issue 60 (Backfire) John Martin reveals that the industry limits the selection of engine lube oils marketed to ordinary consumers, but that formulations under special labels are available to fleet operators and drivers with more exacting standards. 138 Engine lube oil, synthetic, dirty in extended-interval scheduled change. See Engine lube oil, synthetic vs. mineral-based, comparative change intervals Engine lube oil, synthetic vs. mineral-based, comparative change intervals Issue 58 (5.9 HPCR) A shorter drain interval with a less-expensive mineral-based oil may have an advantage over a long-lasting synthetic base, because the limiting constant in both is the action of the additive package. 39 Engine lube oils, API CI-4/CJ-4, differences in performance, testing, and opinions about. See also Engine lube oils, lab analysis, comparison and evaluation Issue 58 (Backfire) Editor Patton, reflecting on exchange of letters between Amsoil and John Martin ref. deficiencies in CJ-4 for pre-’07 vehicles, concedes that CJ-4 oils “aren’t that bad—they’re just different.” 152 Issue 58 (Backfire) AMSOIL faults test procedure reported in TDR Issue 57, pp. 56-60, for evaluating performance of API CI-4 and CJ-4, claiming that field testing is inadequate and that only the industry’s expensive computerized lab tests are reliable. 150–153 Issue 58 (Backfire) Responding to Amsoil’s criticism of tests on CI-4 and CJ-4 lubes reported in TDR Issue 57, John Martin concedes that each oil has its pluses, but maintains that CI-4 offers better performance for pre-’07 vehicles. 150–153 Issue 59 (Have Ram, Will Travel) Joe Donnelly concurs in TDR consensus that API CI-4 performs better in Turbo Diesels made prior to current requirement of CJ–4 to safeguard the particulate filter on new models, and is stockpiling the superseded oil. 92 Issue 59 (Backfire) John Martin continues his survey and analysis of engine oils, with additional comments on the debate surrounding the relative merits of API CI-4 vs. CJ-4, further arguing the superiority of the superseded formula. 124–126 Engine lube oils, lab analysis, comparison and evaluation Issue 57 (Technical Topics) With the editor’s input of background data, John Martin tests 21 brands of diesel engine oil, to yield rating figures for eight lab variables and retail prices. 56–60 Issue 58 (Technical Topics) The editor updates John Martin’s lab analysis and evaluation of competing brands, continued from Issue 57, pp. 56-60. 54 Engine oil drain valve, Fumoto brand. See Accessories, added by the editor to his new Mega Cab Engine operation, running out of fuel. See Engine priming, troubleshooting failure in Engine priming, troubleshooting failure in Issue 58 (First Generation) A lift pump in a First Generation truck which fails to deliver fuel and re-prime is replaced to correct a problem in running out of fuel. 16 Engine startup, failure at low temperatures Issue 60 (5.9 HPCR) After many unsuccessful attempted fixes, an engine’s failure to start in low ambient temperatures was corrected by replacing the fuel control actuator. 39 Engine startup problems, troubleshooting. See also Starter solenoid, failure, troubleshooting; See also Automatic transmission indicator, adjustment of; See also Fuel heater, failure; See also Startup problems, troubleshooting; See also Clutch safety start switch, replacement Issue 57 (12-Valve Engines) A TDR member suggests that the cause of intermittent starter problems in his ‘95 truck may be slippage in the seating of starter contacts, recently replaced. 34 Issue 57 (12-Valve Engines) Members pool suggestions for troubleshooting intermittent startup failure, including fuses, batteries, battery connections, ground to solenoid and relay circuits, and mechanical linkages. 34 Issue 57 (6.7 HPCR) Members report startup failures in the 6.7 HPCR engine, a pattern explained by a locking up of the wireless control module (WCM), correctable by an ignition-key switching stratagem. 52 Issue 58 (12-Valve Engines) Hard starting with the engine angled uphill indicates a leak in fuel hose, which should be replaced with diesel-rated hose. 24 58 www.turbodieselregister.com TDR 61 Issue 58 (12-Valve Engines) Problems in starting the engine and achieving idle are traced by readers to a malfunctioning lift pump. 24 Issue 59 (12-Valve Engines) Intermittent starting in a ‘97 Turbo Diesel is cured by replacing the fuel shut-off relay powering the fuel shut-off solenoid. 28 Engine tapping noise, troubleshooting Issue 60 (5.9 HPCR) A reader reporting intermittent engine miss and tapping sound (which he was not able to trace to visible defects in springs, keepers and valves) is counseled by Joe Donnelly to consider a dropped valve seat or stuck FCA on the CP3. 38 Environment, ecosystem endangered by population explosion Issue 60 (Blowin’ In The Wind) The underlying explanation of the worldwide energy crisis and cause of threatening catastrophe in terms of sustainable civilization is the uncontrolled, and probably uncontrollable, population explosion, says Ken Freund. 55 EPA 2010 emissions standards, met by the new 6.7-liter engine Issue 57 (6.7 HPCR) Joe Donnelly explains how it is that the Cummins 6.7-liter Turbo Diesel engine was able to comply fully with demanding EPA emission standard, effective through 2012. 54 EPA demands and industry responses, constants in the industry Issue 59 (Ranch Dressing) John Holmes remarks that in the face of continual change some things abide, citing a pattern over fifty years as increasingly restrictive emissions standards elicit continuing development. 64 Issue 59 (Celebrity Corner) Sam Memmolo writes about evolving emissions standards over the years, and manufacturers’ responses, including EGR, catalytic converters, and computer systems; and sees the process being repeated with particulate filters. 83–85 Events 2007. See also May Madness 2007 Issue 57 (Have Ram, Will Travel) The annual “Mopars at the Strip,” which saw an impressive range of dyno results, was held at the Speedway complex, Las Vegas, NV, Mar. 30– Apr. 1. 120 Issue 57 (Chapter News) Scott Dalgleish reports on Dyno Days event, sponsored by Dynomite Diesel Performance, Monroe, WA, open to all diesel-powered vehicles. 131 Issue 57 (Out Standing In The Field) Perfection Clutch Open House and Dyno Daze (Pee Dee Diesel Dyno Daze), Sept. 22, Timmonsville, SC. 132–134 Issue 57 (Out Standing In The Field) Scheid Diesel’s Diesel Extravaganza was presented Aug. 24–26, Terre Haute, IN. 132–134 Issue 57 (Out Standing In The Field) Second Annual TST Dyno Day, was held on Oct. 6, Columbus, IN. 132–133 Issue 58 (TDRelease) J&H Performance Diesel, Redding, CA, thanks members of TDR who attended the Nor-Cal Diesel Rally ‘07 for contributing to its success, and advertises its service facilites. 157 Issue 60 (Chapter News) Jim Anderson tells of the first Florida Snow Bird gathering split into two events, one in early January and the second in February at Lakeland, with accounts of seminars and discussion groups. 101 Issue 60 (Chapter News) Joe Donnelly publicizes the New Mexico TDR Chapter Dyno Day, held December 2007 in the Albuquerque area, with details of sponsors and events; also names, facts, and figures in the dyno competition. 101 Issue 60 (Chapter News) Mid-Tennessee TDR Chapter met late February, sponsored by Cedar City Diesel, Lebanon, TN. 102 Issue 60 (Chapter News) Northwest Bombers held their 9th annual party, this year in Enumclaw, WA, celebrated with shared food, mud pit, monkeywrenching, and general merriment. 102 Events 2008 Issue 58 (Out Standing In The Field) In this issue TDR presents the calendar of events, both those reserved for Turbo Diesels and those open to other diesel pickups, scheduled in 2008. 128 Issue 59 (Out Standing In The Field) Fourteenth Annual May Madness is scheduled for May 5–10, ‘08, Pahrump, NV; and Joe Donnelly provides promotional description and registration material. 102–104 Issue 60 (Out Standing In The Field) Joe Donnelly announces the Fourteenth Annual May Madness, May 5–May 10, Pahrump, NV, gives details, and provides the official registration form. 104–106 Exhaust brake, advisable Issue 58 (From The Shop Floor) Andy Redmond declares an exhaust brake a must-have accessory for towing in mountainous terrain, gives tips on use with automatic transmissions, and recommends both BD and Pacbrake brands. 149 Exhaust brake, installation, with compound turbochargers Issue 60 (5.9 HPCR) Doug Leno details installation of the Pacbrake PRXB exhaust brake and onboard air compressor particularly compatible with a ‘04 Turbo Diesel using Aurora-5000based compound turbochargers that he had described in Issue 53, p. 44. 34–36 Exhaust brake, on vehicles with 6.7-liter engine Issue 59 (6.7 HPCR) All 6.7-liter Turbo Diesels are equipped from the factory with an exhaust brake, reportedly much more effective than the add-on units available in the past, evoking wide reader acclaim. 40 Exhaust brake with the 68RFE transmission, questions Issue 57 (6.7 HPCR) A member asks if the exhaust brake equipped with the new 68RFE automatic transmission can be used full-time without damage, and gets a thumbs-up from a correspondent in the field as well as a positive assessment of the unit. 52 Exhaust gas temperatures, excessive, as cause of “dropped” valve seat Issue 57 (Have Ram, Will Travel) Joe Donnelly publishes a picture of a “dropped” valve seat in a ‘04.5 model year cylinder head caused by excessive exhaust gas temperature. 120 Exhaust manifold, aftermarket, multi-piece, upgrade Issue 58 (12-Valve Engines) Joe Donnelly says that almost every stock manifold he has seen on 12-valve engines has significant shrinking and advises replacement with the threepiece exhaust manifold. 26 Exhaust noise, reducing Issue 57 (24-Valve Engines) An operator stopped by police for a loud exhaust is advised by Joe Donnelly to get a muffler, at a minimum a straight-through muffler. 36 Exhaust system, aftermarket Issue 57 (TDRelease) ANSA Automotive announces a new 5” single-unit performance exhaust system for ‘04–’07 models of the Turbo Diesel pickup. 161 Exhaust system, low-restriction. See Low-restriction exhaust and airbox system TDResource . . . . Continued Exhaust systems, 4” vs. 5” compared Issue 57 (5.9 HPCR) Joe Donnelly points out that a 5” exhaust with a 4” downpipe does little to improve performance, but that in general less restriction benefits spoolup and the larger bore modestly improves hp. 40 Exhaust tip, six-inch model, aftermarket Issue 57 (TDRelease) ANSA Automotive offers a black stainless version of its 6” Diesel Truck Tip, which resists smudging and hides exhaust soot stain. 161 Extrude honing Issue 59 (Member2Member) To a reader seeking information on injector flow-testing and the process of extrude honing, Joe Donnelly references shops with necessary equipment and coverage in TDR Issues 56, p. 97; 57, p. 45; and 59, pp. 86-89. 16 Fan shroud, removing. See also Dowel pin problem Issue 59 (Have Ram, Will Travel) Noting a reader resorted to cutting the fan shroud to access the front-mounted gear case, Joe Donnelly offers the alternative of removing it mechanically, and provides instructions for a simple non-destructive procedure. 92. FASS brand fuel transfer pump and filter, information. See Fuel transfer (lift) pump, aftermarket replacement FASS fuel pump, noise reduced in new models Issue 57 (TDRelease) Diesel Performance Products announces that noise of the FASS pump has been reduced by up to 11 decibels. 162 Fender seal, for dually model truck Issue 60 (First Generation) Either Volkswagen rubber seal or an Arrowcraft specialty kit will seal between the fiberglass fender and the box fender. 14 Fifth-gear nut problem Issue 58 (12-Valve Engines) To a reader rebuilding his NV4500 and seeking a source for a 5thgear nut, Joe Donnelly advises that the best way to go is with a fully splined mainshaft upgrade by Standard Transmission & Gear. 28 Issue 59 (Member2Member) Brad Nelson describes the damage to his NV4500 transmission caused by a broken fifth-gear nut, and details his repair, including a new, fully-splined countershaft, both upper and lower fifth gears, and a new main shaft. 14–15 Issue 59 (Idle Clatter) According to Jim Anderson, who clarifies the cause of the fifth-gear nut problem, the best fix is a replacement with a fully splined transmission output shaft such as those made by Standard Transmission and Blumenthal Heavy Duty. 60 Fifth-wheel, tow vehicles for heavier-duty hauling. See Turbo Diesel ‘08 4500/5500, specs for hauling weights Fifth-wheel trailer, stabilizing jacks, aftermarket Issue 57 (TDRV) Testing products in seeking to stabilize a parked fifth-wheel trailer, Jerry Nielsen compares the conventional tripod to a jack made by Plug-it-right, judges the latter superior, and gives instructions for using it. 149 Fifth-wheel trailer hitch, Reese slider brand Issue 60 (TDRV) Readers compare experiences with performance of the Reese fifth-wheel slider hitch. 129 Fight-or-flight: managing autonomic response to challenge Issue 60 (Motor-Minded) Mark Barnes explains the interaction of brain cortex and limbic system and autonomic system in triggering the “fight or flight” response to emotional challenge, and applies it to buying truck accessories. 68–69 Fire hazards in RVs Issue 57 (TDRV) Jim Anderson describes fire hazards in RVs, in both the electrical and the propane systems, and prescribes the necessary precautions. 146–147 Five Points Tour Issue 59 (Five Points Tour) Josep and Judith Gagnon, Colchester, VT, are the most recent members completing the Five Points Tour through continental U.S. 128 Issue 59 (Five Points Tour) The TDR continues its sponsorship of the Five Points Tour to encourage continental travel among members, and provides rules and incentives. 128–129 Floor mats, aftermarket. See also Accessories, added by the editor to his new Mega Cab Issue 58 (Member2Member) Bill Stockard considers the Mopar floor mats as “Must Haves” on any new truck. 10 Forbus, Melissa, her story Issue 60 (Your Story) Melissa Forbus, diesel enthusiast, granddaughter of TDR teammates Bob and Nancy Simerly, tells of schooling to be a diesel technician, organizing sled-pulls for the Nevada State Fair, and fun with her First Generation truck. 134–135 Ford, diesel-engine problems in ambulance vehicles Issue 59 (Idle Clatter) With a large share of the market for ambulance vehicles, Ford’s ill-fated 6.0-liter diesel engine has caused serious problems: excessive downtime for users and huge warranty costs for the manufacturer, according to Jim Anderson. 59 Ford, legal tangle with Navistar’s International Truck and Engine Issue 58 (Idle Clatter) Jim Anderson reports on Ford’s long-running legal contest with International Truck and Engine after reneging on agreement to buy a V-6 diesel engine for a projected light-duty pickup. 61 Ford, potential parts-availability problems for owners Issue 58 (Idle Clatter) Jim Anderson reflects on problems Ford truck owners may have in finding replacement parts for diesel engines Ford discontinues after brief production runs. 62 Four-wheel drive indicator lights, confused signals Issue 59 (24-Valve Engines) TDR readers identify reversed vacuum lines at the central axle disconnect (CAD) as the reason indicator lights on the dash reverse the correct readings of four-wheel drive engagement. 34 Front end alignment, computerized Issue 58 (Have Ram, Will Travel) Joe Donnelly says that modern computerized front-end alignment gives superior results, and he recommends West Side Auto in Albuquerque to improve tracking. 125 Fuel/water separator, sensor failure, in First Generation trucks Issue 60 (First Generation) Failure of the fuel/water separator warning light on the dash of First Generation trucks may indicate a defunct sensor, defective attached sensor board, corroded wiring, or other failures in the circuit. 18 Fuel additives, forbidden in the 6.7-liter engine Issue 57 (Ranch Dressing) John Holmes reminds readers that Cummins enjoins against use of fuel additives in the 6.7-liter engine. 102 Issue 58 (6.7 HPCR) The editor warns that because of new emission control devices in the ‘07.5 and newer 6.7 liter engines, fuel additives are contraindicated, i.e., verboten, forbidden, a no-no. 42 Issue 59 (Letter Exchange) Operators of vehicles with the 6.7-liter engine are advised to follow instructions of the vehicle’s warranty guarantor, Dodge or Cummins, where they differ on rules for fuel additives. 8 Fuel additives, use in engines since ‘98.5 but prior to ‘07.5 Issue 58 (6.7 HPCR) The editor reviews advice on use of fuel additives in recent model Turbo Diesel engines prior to the 6.7-liter engine, with recommendation of specific products. 42 Fuel adjustment screw, leak at, repairing of Issue 57 (First Generation) Members solve the problem of a leak at the fuel screw by replacing the O-ring seal. 24 Fuel control actuator (FCA), cause of poor drivability Issue 60 (Have Ram, Will Travel) Rough running, poor idling, fuel knocks are symptoms suggesting a bad fuel control actuator on the HPCR CP-3 high pressure pump, says Joe Donnelly. 92 Fuel control actuator (FCA), explained Issue 59 (5.9 HPCR) The CP3 pump’s fuel control actuator (FCA) controls fuel rail pressure and delivery; and malfunction causes rough idling, rough running, and rattling from a “fuel knock.” 38 Fuel control actuator (FCA), modifying to increase fueling Issue 59 (5.9 HPCR) Joe Donnelly says that the fuel control actuator (FCA) can be modified for more fueling by electrode discharge machining (EDM) and identifies a shop as a source. 38 Fuel delivery remapping, aftermarket kit Issue 57 (Product Showcase) The Power Puck from Diablo Sport is a simple plug-in kit to remap fuel delivery, with three incremental power settings to increase hp and torque. 157 Fuel delivery valve, tool for removing Issue 60 (12-Valve Engines) A member identifies the wrench and socket, available from Cummins and Snap-On, for removing the fuel delivery valve on a 12-valve truck. 20 Fuel door, chrome, locking, Bully brand. See Accessories, added by the editor to his new Mega Cab Fuel efficiency, driving habits as paramount parameter Issue 60 (Have Ram, Will Travel) After considering design factors and variable constraints of power modifications made to the equipment, Joe Donnelly emphasizes that bad driving habits contribute most to low fuel efficiency. 90–91 Fuel efficiency, meeting the 2020 mandate of 35 mpg CAFE. See also Fuel efficiency, meeting the technological challenge Issue 60 (Blowin’ In The Wind) Greg Whale counsels that reality will prevail eventually in the application of the 2020 mandate of 35 mph CAFE, with accommodation to heavy drayage trucking and evolving comsumer expectations. 60 Issue 60 (Blowin’ In The Wind) In evaluating the impact of Congress’ mandate for 2020 of 35 mpg, the editor points out that the technology and the vehicles are available even today, and that eventually buyer resistance will crumble. 60 Issue 60 (Blowin’ In The Wind) The laws of physics and the realities of politics will make it virtually impossible for industry to fully meet the 2020 mandate of 35 mpg CAFE without loopholes and escape clauses, says Forbes’ magazine. 61 Issue 60 (Four Whaling) CAFE numbers can be decreed from on high, but they are ultimately unworkable, given the needs of end users, the limitations of engine design, and the realities of market dynamics, argues G. R.Whale. 62–63 Fuel efficiency, meeting the technological challenge Issue 60 (Exhaust Note) Although the world energy challenge is severe, technology is capable of meeting emissions standards, says Kevin Cameron, who reviews advanced techniques available, including HCCI, Homogeneous Charge Compression Ignition. 151–153 Fuel efficiency, reconciling with power increases. See Power increase and fuel efficiency, achieving both Fuel filter stained black, explanation of Issue 59 (24-Valve Engines) Asphalt compounds normally present in diesel fuel account for the black stain residue in used fuel filter elements. 34 Fuel heater, failure Issue 58 (12-Valve Engines) A TDR member identifies a fried pin on the fuel heater as the cause of engine startup problems. 24 Fuel heater, instructions for removal Issue 60 (First Generation) A member is provided with an assessment and tips for how to remove a recalcitrant stud attaching the fuel heater in a First Generation truck. 18 Fueling increase, by aftermarket injector pump cam plate Issue 60 (12-Valve Engines) Joe Donnelly advises that fueling may be effectively increased in 12-valve engines by installing a TST power kit with a modified injector pump cam plate. 20 Fuel injection line, chronic failure, troubleshooting Issue 58 (5.9 HPCR) According to Joe Donnelly, injector lines, particularly #4 and #6, are liable to failure from vibration permitted by missing bracket or kinks and twists, correctable through careful servicing. 39 Fuel injection pump, “hot rod” VP44 version Issue 58 (24-Valve Engines) Joe Donnelly describes the popularly-known “hot rod” VP44 injection, available from a Bosch rebuilder, and discloses the hp gain for the High Output 24-valve Turbo Diesel engine. 35 Fuel injection pump, CP3, changing Issue 60 (5.9 HPCR) A reader seeking information on changing fuel injectors and the CP3 pump in his ‘06 truck is referred by Joe Donnelly to articles in Issue 51, p. 97, and Issue 56, p. 107. 38 Fuel injection pump, VP44, changing units Issue 57 (24-Valve Engines) A member seeking instructions for changing out the VP44 injection pump is directed by Joe Donnelly to Issue 51, p. 96. 38 Fuel injection pumps, distinction between two stock units shipped in ‘96–’98 Issue 57 (12-Valve Engines) Bosch P7100 injection pumps in model years ‘96–’98 have two different part numbers, but are substantially identical, according to Joe Donnelly. 30 TDR 61 www.turbodieselregister.com 59 TDResource . . . . Continued Fuel injection pumps, VP44 and P7100, specs for shaft-nut sizes Issue 57 (24-Valve Engines) Joe Donnelly provides the specs for the drive gear retaining nuts on both the VP44 and the P7100 model injection pumps, respectively. 38 Fuel injector, body and tips, specifications for Issue 57 (24-Valve Engines) While they carry different part numbers, the fuel-injector bodies of both the high-output and non-high-output engines are internally identical. 38 Fuel injector, troubleshooting Issue 59 (5.9 HPCR) Joe Donnelly identifies methods to test fuel injectors, engine running, with both DRB scan shop tool and infrared gun; and advises that the knocking and vibration a reader complains of may be corrected by replacing the FCA. 39 Fuel injector nozzle, machine modification of. See also Extrude honing Issue 57 (5.9 HPCR) Doug Leno reports the process and results of enlarging injector nozzles by Wire Electrical Discharge Machining (wire-EDM) and polishing by Abrasive Flow Machining (AFM) to achieve profound improvements in fuel delivery. 44–49 Fuel injectors, DDP brand, installation. See DDP injectors, installation Fuel injectors, installation, precautions Issue 57 (12-Valve Engines) Joe Donnelly reviews precautions, safeguards, and specs for successful, trouble-free installation of injectors. 32 Fuel injectors, servicing Issue 58 (24-Valve Engines) Joe Donnelly says that habitual extended idling will cause fouling of injector tips, requiring cleaning or replacing, and that extended mileage causes weakening of pop-off springs, requiring re-set by a Bosch repair shop. 35 Fuel injectors, upgrade, result in lower mpg Issue 60 (Back In The Saddle) Installation of DDP 90 Horsepower injectors, reported in Issue 59, makes Scott Dalgleish’s Turbo Diesel more fun to drive, but results in a 6% drop in fuel economy; so he recommends sticking with the 50 horsepower injectors. 84 Fuel injector upgrade, criteria and guidelines Issue 57 (12-Valve Engines) Responding to a member seeking the “biggest” injector upgrade for his ‘97 automatic Turbo Diesel, Joe Donnelly reviews the critical considerations and recommends 370 horsepower marine injectors. 32 Issue 57 (24-Valve Engines) To a reader seeking a modest power increase in an “almost stock” 24-valve, five-speed work truck, Joe Donnelly recommends the 275 horsepower RV injectors. 36 Issue 57 (5.9 HPCR) Joe Donnelly tells how to choose aftermarket injectors on later model Turbo Diesels. 40 Fuel injector wiring harness, pre-attached nuts Issue 57 (5.9 HPCR) A member worried about losing a nut when replacing an injector wiring harness is reassured that the nuts are pre-attached to the harness. 42 Fuel leak at high pressure lines, diagnosing and correcting Issue 60 (24-Valve Engines) Joe Donnelly diagnoses leakage where the high pressure fuel line connects to the head, provides instructions for cleaning and re-fitting, and answers a question about the right torque when re-installing the line. 28 Fuel lift pump. For entries under this heading, See also entries at Fuel transfer pump Fuel lift pump, advice for installing Issue 57 (First Generation) Just so long as the bolts are down tight, specific torque specs are not crucial in installing a diaphragm-type lift pump on a First Generation engine. 26 Fuel lift pump, estimating its service lifetime Issue 57 (5.9 HPCR) In response to a member asking if 67,000 miles approaches the limits of a lift pump’s expected service life, Joe Donnelly answers that even only a single power enhancement may overwhelm the capacity of the stock item. 40 Fuel lift pump, FASS benefits and installation Issue 60 (Back In The Saddle) Although OEM in-tank lift pump has been adequate with the Bosch CP3 in his ‘06 truck, Scott Dalgleish opts for the FASS system, the benefits of which he itemizes and explains. 84–86 Fuel lift pump, high-performance, for 12-valve engines Issue 59 (12-Valve Engines) In response to the question of why there is no high-performance aftermarket lift pump for 12-valve engines, Joe Donnelly says there would be little call for it because the stock pump is itself so efficient and reliable. 30 Fuel lift pump, malfunction, troubleshooting Issue 58 (First Generation) Difficulty in starting a First Generation truck after running out of fuel is corrected by replacing the lift pump. 16 Issue 58 (12-Valve Engines) TDR readers trace lift-pump problems in starting and idle, fixed by replacing the pump, fuel screen and filter, and eliminating the fuel heater. 24 Issue 58 (24-Valve Engines) A lift pump on a 24-valve engine which continues to run after the ignition is turned off is addressed by replacing the fuel relay. 34 Fuel lift pump, replaced with the FASS system Issue 57 (24-Valve Engines) In response to reader seeking a lift pump superior to the stock item on his 2001 Ram, Joe Donnelly notes the merits of the FASS system and recommends a fuel pressure gauge. 36 Fuel lift pump, source of ticking noise Issue 59 (12-Valve Engines) An under-hood ticking sound is traced to the lift pump and may be caused by constricted fuel filter or, more likely, a gradually weakening return spring, indicating impending failure and replacement of the unit. 26 Fuel lift pump, stock on 12-valve engine, maximum hp enhancement tolerated Issue 57 (12-Valve Engines) Joe Donnelly reports successfully upgrading to 800 hp. with a stock lift pump in a 12-valve engine. 30 Fuel lift pump pre-filter, fouled Issue 58 (12-Valve Engines) Debris in the lift pump pre-filter can foul the lift pump, causing startup and ignition problems. 24 Fuel mileage calculator, overhead console, accuracy of Issue 57 (Idle Clatter) Jim Anderson notes that the overhead electronic fuel-mileage calculators are chronically inaccurate, off as much as 2 mpg, in his experience. 80 Fuel obstruction, troubleshooting Issue 58 (Idle Clatter) Jim Anderson tells of a friend plagued by engine woes and inexplicable dying, finally traced to a rag accidentally left in the tank during a pump replacement. 60 Fuel pressure gauge. See Gauges, auxiliary Fuel pump lever, identifying the correct running position Issue 57 (First Generation) Readers resolve contradictory information in the service manual on whether the normal running position of the fuel pump lever is up or down. 22 60 www.turbodieselregister.com TDR 61 Fuel shut-down, troubleshooting Issue 60 (12-Valve Engines) A reader suspects the solenoid when he must lift shut-off manually before he can start his 12-valve engine; he is advised to lubricate plunger, replace relay on the firewall, and check wire with fusible link from the battery. 20 Fuel system malfunction, troubleshooting Issue 59 (Ranch Dressing) John Holmes surveys the range of diagnostics specific to the modern diesel fuel injection system, including the simple ones that show up as a DTC, but some more technical, requiring a well-equipped shop. 66 Fuel tank. See also Refueling tank, 50 gallon, aftermarket Fuel tank, combo 40-gallon with tool box Issue 60 (TDRelease) Transfer Flow, Inc., markets a 40-gallon fuel tank combined with a toolbox boasting over 5 1/2 cu.ft. capacity, made of 14-gauge aluminized steel, which will mount flush with bed rails to clear fifth-wheel trailer hitch assemblies. 144 Fuel tank sending unit, methods for accessing Issue 57 (First Generation) Readers compare methods to access and replace the fuel tank sending unit on First Generation trucks, including removal of bed and lowering the tank. 22 Fuel transfer pump. For entries under this heading, See also entries at Fuel lift pump Fuel transfer (lift) pump, aftermarket replacement Issue 58 (Member2Member) Joe Donnelly reminds readers that, as horsepower is increased in the Turbo Diesel, a system like the FASS becomes increasingly advisable. 8 Fuel transfer pump, aftermarket, installing in ‘03–’04.5 engines Issue 60 (5.9 HPCR) The editor describes the process of installing an aftermarket transfer pump marketed by Fel Pro, available at Geno’s, suitable to replace a defective stock pump in ‘03–’04.5 engines. 31–32 Fuel transfer pump, location on the engine vs. under the cab Issue 58 (Backfire) A Canadian reader says winter road salting destroys aftermarket under-thecab lift pumps, opts for the OEM on-the-engine unit, and names Delphi as a source of the difficult-to-find replacement. 153 Fuel transfer pump, source for replacement of stock in ‘98.5–’02 engines Issue 60 (5.9 HPCR) In continuing coverage of how members cope with the limitations of the stock transfer pump, the editor alerts the readership to aftermarket availability of replacements from Delphi and FelPro from Geno’s for less than $200. 30 Fuse failure, cause of multiple function failures Issue 60 (12-Valve Engines) As demonstration of the axiom “check the obvious first,” readers discover that failed tachometer, speedometer, overdrive, and shut-down solenoid were all caused by a failed fuse in the PDC of a 12-valve truck. 21 Gauge pod, A-Pillar location Issue 59 (6.7 HPCR) Readers find that the A-pillar gauge pod listed for ‘02–’06 model years in the catalog of Geno’s Garage is a perfect fit for trucks with the 6.7-liter engine. 40 Gauges, auxiliary Issue 58 (Member2Member) For late model Turbo Diesels, Joe Donnelly identifies his favorite gauges—both those sold with power-enhancement packages and those not so packaged—available at Geno’s Garage. 8 Issue 58 (From The Shop Floor) Andy Redmond describes the function of gauges—pyrometer, boost, fuel pressure, temperature—and provides tips on wiring and mounting. 148 Gauges, deemed essential Issue 59 (First Generation) To get the best performance from Turbo Diesel pickups, monitoring gauges are essential: in order of importance, EGT; Boost; Transmission temperature; tachometer; fuel pressure. 22 Issue 59 (5.9 HPCR) Readers consult on which three of the four popular gauges are more essential in a 5.9 HPCR engine with automatic transmission: boost, EGT, fuel pressure, or transmission temperature. 36 Issue 60 (Have Ram, Will Travel) Joe Donnelly reviews several fuel and rail pressure gauges, available at Geno’s Garage, which he deems essential in responsible operation of Third Generation Turbo Diesel trucks. 91 Gauges, installation. See Accessory installation, in-cab, savvy advice for simplifying the job Gauges, Isspro brand. See Accessories, added by the editor to his new Mega Cab Gauges, modifying a three-gauge pod to accommodate five Issue 59 (5.9 HPCR) A member describes his modification of a three-gauge mounting pod to accommodate five function gauges, all available from Geno’s Garage. 36 Gear case. See Timing gear case Gear lube oils, compared Issue 59 (Member2Member) Joe Donnelly refers readers to a Website publication of comprehensive research results on tests on gear lubes, and also to his own coverage of the topic in current issue, TDR 59, p. 92. 16 Issue 59 (Have Ram, Will Travel) Joe Donnelly reproduces a table of results in an Amsoil test comparing critical performance criteria in fourteen brands of SAE 75-90 synthetic gear lube oils. 92 Gooseneck trailer hitch. See Trailer hitch, gooseneck, installing Governor springs. See Injection-pump governor springs, replacing GPS (Global Positioning System), aftermarket Issue 58 (Member2Member) While he doesn’t consider it as exactly “essential,” Bill Stockard says that the Garmin StreetPilot 2620 is his “preferred favorite accessory” for any truck, old or new. 11 Grease, excessive, cause of clutch slipping Issue 59 (Member2Member) Doug Leno finds that grease applied too liberally to the transmission input shaft during clutch installation can contaminate the clutch facings, causing premature failure. 12–13 Grille guard Issue 60 (Ranch Dressing) John Holmes discusses the need for an effective grille guard, especially in driving where wild life abounds, selects a superior product made by Top Gun, and provides advice and instructions for its installation. 74–75 Grounding problems, source of problems in electrical systems. See Electrical problems, troubleshooting, tools, and fixes Head. See Cylinder head, general service procedures when replacing Head bolts, whether to replace after removing head gasket Issue 60 (12-Valve Engines) Joe Donnelly observes that generally head bolts are reusable, even after increases of power and boost pressure. 21 TDResource . . . . Continued Head gasket, instructions for replacing Issue 57 (12-Valve Engines) For a truck with a coolant leak at the head gasket in an engine with enhanced power, Joe Donnelly advises upgrade to a marine-type product, and gives instructions for doing the job. 30 Head gasket, leak, instructions for redressing Issue 58 (12-Valve Engines) Joe Donnelly provides analysis and instructions to correct a head gasket leak in a 12-valve engine with 200,000 miles, with admonition to seek a shop that will assure an OEM-like finish to the head. 26 Headlight replacement, on all models Turbo Diesel trucks Issue 57 (From The Shop Floor) Andy Redmond provides list of tools, replacement parts numbers, instructions for replacing the headlight housings, and a guide to calibrating and lining up the projected beams for Turbo Diesel trucks. 151–153 Headlights, intermittent failure, troubleshooting Issue 60 (First Generation) A TSB on intermittent headlight failure calls for a switch replacement kit, which, with new relays, solves the problem in First Generation trucks. 16 Headliner, in-cab, replacement in First Generation trucks Issue 60 (First Generation) Readers replace decaying in-cab headliners in older trucks, providing instructions and improvising suitable fabrics, backings and adhesives. 16 Head studs. See ARP head studs Health care on the road for RVers Issue 58 (TDRV) Polly Holmes reviews essential information on highway health care for RVers as it was presented by Linda C. Brown R.N., at the Good Sam RV Rally 2007, Richmond, OR. 162 Heater, malfunction, troubleshooting. See Engine coolant temperature, erratic overheating, troubleshooting Heater, Ventilation, Air Conditioning (HVAC) system, noise and vibration Issue 58 (5.9 HPCR) A broken recirculation door in the HVAC system or a loose fan blade will cause vibration and noise, common enough that it called for a TSB, reference to which is provided. 36 Heater blower control switch, troubleshooting Issue 57 (First Generation) Dry motor bearings in the heater blower are identified as the cause of switches repeatedly burning out in First Generation trucks. 24 Heater core, replacing Issue 59 (12-Valve Engines) For instructions on replacing the heater core in a Turbo Diesel pickup, Joe Donnelly refers readers to his exposition on the subject, TDR Issue 46, an abbreviated version of which is found in the current issue, 59, pp. 90-91. 30 Issue 59 (Have Ram, Will Travel) Joe Donnelly summarizes, with illustrations, his exposé on replacing the heater core in a Turbo Diesel engine originally appearing in TDR Issue 46, pp. 12–15, including instructions in the procedure and a tool list. 90–91 Heater failure, troubleshooting. See Engine coolant temperature, erratic overheating, troubleshooting High-mileage vehicles, TDR recognition of. See TDR emblems, plates, and tags Hitch/tailgate step, aftermarket. See Bed step, at tailgate entry, aftermarket Holmes, John, announces retirement from Carson Dodge Issue 59 (Ranch Dressing) Lamenting the IRS rules which determined it, John Holmes announces his retirement from Carson City Dodge, Carson City, NV. 70 Honors and recognition awards Issue 57 (TDR/R/R) TDR adds to its roster of honorees for enlisting new members, high mileage, and other distinctions in the Turbo Diesel world. 135–139 Issue 58 (TDR/R/R) TDR adds to its roster of honorees for enlisting new members, high mileage, and other distinctions in the Turbo Diesel world. 132 Issue 59 (TDR/R/R) TDR adds to its roster of honorees for enlisting new members, high mileage, and other distinctions in the Turbo Diesel world. 105–107 Issue 60 (TDR/R/R) TDR adds to its roster of honorees for enlisting new members, high mileage, and other distinctions in the Turbo Diesel world. 108–111 Hood scoop, SRT-10, Mopar. See Accessories, added by the editor to his new Mega Cab Hose, mysterious, dangling from rear brake assembly Issue 58 (5.9 HPCR) One reader informs another that a “mystery hose” dangling from the rear axle is not part of the brake system but is a disattached differential vent hose. 38 Hoses, silicone, aftermarket Issue 60 (Member2Member) Responding to a reader asking if stock boost hoses will perform with a twin turbo upgrade, Joe Donnelly recommends replacement with Mr Bob’s hoses. 13 Issue 60 (First Generation) Readers concur in preference for high-quality aftermarket silicone in replaced small coolant and heater hoses. 16 Issue 60 (Have Ram, Will Travel) Joe Donnelly suggests replacing the turbo compressor hose and other boost hoses in the Third Generation truck with Mr Bob’s high-quality blue or black silicone hoses. 93 Hot fuel, update. See Diesel fuel, inaccurate measurement at the pump HVAC. See Heater, Ventilation, Air Conditioning (HVAC) system, noise and vibration Idle, fading after startup Issue 58 (12-Valve Engines) In several postings about problems with idle fading after startup, readers trace the problem to bad lift pump, leak in fuel hose, fouled pre-filter, and failed fuel heater. 24 Idling, extended, perils of Issue 58 (24-Valve Engines) Joe Donnelly emphasizes that extended idling will inevitably cause deposits on tips of fuel injectors, requiring cleaning and/or replacement. 35 Idling, poor. See Fuel control actuator (FCA), cause of poor drivability Idling, rough. See Fuel control actuator (FCA), explained Index, TDR Issues 53–56 Issue 57 (TDReSource) This index to issues 53–56 accesses technical information arranged alphabetically by topic with brief informative annotations. 88–100 Injection-pump governor springs, replacing Issue 58 (12-Valve Engines) Joe Donnelly describes replacing the governor springs on a 12-valve engine, with cautions and instructions. 28 Injection lines, 12-valve engine, Cummins stock Issue 58 (12-Valve Engines) Responding to a reader’s query, Joe Donnelly says that the injector lines on the 12-valve engine are made of gold cadmium-plated steel painted black. 28 Injection pump, Bosch VE, source for seal kit Issue 58 (First Generation) Readers supply part number and source of a seal kit for the Bosch VE injection pump. 17 Injection pump, CP3, maximum power upgrade with Issue 60 (5.9 HPCR) The stock CP3 fuel injector pump will support power upgrades to around 565–600 hp, beyond which level any combination of power adders will be of little avail, says Joe Donnelly. 36 Injection pump, dual CP3 aftermarket kit Issue 60 (TDRelease) Industrial Injection Service is marketing a dual CP3 kit which provides a second pump in applications with the common rail Cummins engine. 144 Injection pump key, lost and found. See Timing gear housing, removal to retrieve alignment key Injector nozzles, for 6.7-liter engine, aftermarket Issue 59 (TDRelease) Proclaiming higher horsepower and better fuel efficiency, a news release from Dynomite Diesel Performance describes its DDP performance injector nozzles for the 6.7-liter Turbo Diesel engine. 135 Injector nozzles, ten-hole, aftermarket Issue 60 (TDRelease) Kerma TDI announces what it calls the Bosio Powerplus, 10-hole Stage 2 and Stage 3 nozzles for Cummins HPCR engines, model years 2003-2007, claiming increased power, low smoke, improved fuel economy. 146 Injector upgrade, specs on performance improvement Issue 60 (12-Valve Engines) Responding separately to two member queries, Joe Donnelly describes the improvements in performance which may be expected from several upgrade injectors in particular applications in the 12-valve engine. 22–23 Intake air temperature (IAT) sensor, removal Issue 59 (24-Valve Engines) Members collaborate in spelling out the procedure in accessing the IAT (Intake air temperature) sensor, a simple and straightforward job. 34 Integrated Power Modules, function of Issue 58 (Ranch Dressing) Although servicing them is beyond the resources of most drivers, for their information John Holmes explains and describes the OEM on-board control modules in the Turbo Diesel truck, their types, including the PDC, FCM, and TIPM. 105 Intercooler, aftermarket replacement Issue 60 (5.9 HPCR) Joe Donnelly suggests the BD intercooler as a replacement which offers bigger inlet and outlet fittings, more frontal area and efficient extruded cores; and reduces EGT compared to stock. 38 Internal combustion engine, benefits to the environment Issue 60 (Blowin’ In The Wind) With a witty excursion on a Rube Goldberg gag, the editor introduces a media essay arguing the benefits to air quality wrought by the internal combustion engine; and proposes maintaining a balanced view on conservation. 54–55 Jeep Grand Cherokee CRD, Benz diesel, evaluation of Issue 57 (Ranch Dressing) John Holmes provides information on a new Jeep model powered by a 3.0-liter Mercedes diesel boasting 215 hp and 375 ft-lb torque. 105 Issue 58 (Four Whaling) Greg Whale describes the Jeep Grand Cherokee CRD powered by a Benz-sourced 3-liter, 24-valve DOHC turbo diesel, and assesses its merits and performance. 80 Jeep Liberty, VM diesel option, performance problems with Issue 57 (Ranch Dressing) John Holmes reports that the diesel version of the Jeep Liberty has been plagued by performance problems, exacerbated by ineffective recall fixes and poor technical support; but notes fixes available from third-party vendors. 104 Jump Box (packet of essential information). See Emergency information packet Killer Dowel Pin. See Dowel pin problem Killer dowel pin, collateral damage. See Timing gear case, instructions for replacing Knocking, pre-ignition off-timing. See Fuel control actuator (FCA), explained Launch shudder. See Rear-end shudder, at launch under load Leaks, various. See the following topic heads: Brake master cylinder reservoir, leaking; Cab clearance light, site of water leak; Coolant leak, troubleshooting; Coolant leak at engine block, troubleshooting; Differential pinion seal, replacing; Fuel adjustment screw, leak at; Fuel leak at high pressure lines, diagnosing; Head gasket, instructions for replacing; Head gasket leak; Oil leak, driver’s-side engine-wall, troubleshooting; Oil-in-coolant discharge from engine; Power steering fluid, leak; Transmission, automatic, cooler lines, leaking; Transmission, automatic, fluid leak suspected; Transmission, 48RE, fluid leak; Transmission, Getrag, oil seepage at vent; Turbocharger drain hose, replacement; Turbocharger drain tube, leak at; Water leak in cab at headliners and grab handles LED (Light Emitting Diode), in RV applications, troubleshooting Issue 57 (TDRV) Jim Anderson notes the increasing use of LEDs in both outside and inside applications in recreational vehicles and provides useful tips and guide to troubleshooting failures. 148 Lock-N-Stitch, bolt-on repair kit for 24-valve “Block 53” engine Issue 60 (From The Shop Floor) To circumvent buying a new Cummins engine to deal with a cracked casting in “Block 53,” a possibility in some late ‘98.5–’04 Turbo Diesels, Andy Redmond favorably reviews Lock-N-Stitch, an unorthodox bolt-on patch kit. 114–115 Long-bed conversion. See Mega Cab, long-bed conversion Low-restriction exhaust and airbox system Issue 58 (Member2Member) Joe Donnelly says that until a Turbo Diesel dyno puts out more than 400 hp, installing low-restriction exhaust and airbox system is not cost effective. 8 TDR 61 www.turbodieselregister.com 61 TDResource . . . . Continued Lube oils, how the industry determines new specifications Issue 60 (Backfire) John Martin describes the process in which new specifications of lube oils are arrived at to meet the requirements of vehicle manufacturers, in a process not always in the best interests of the consumer. 138 Lube oils, special label, for users with strict requirements Issue 60 (Backfire) In his on-going coverage of lube oils, John Martin discusses the industry’s practice of limiting selection and marketing according to its own interests, but reveals availability of special label lubes for users with special needs. 138 Lugging, with 68RFE Issue 57 (6.7 HPCR) A member driving a 6.7 HPCR equipped with the 68RFE automatic transmission is assured that it is unnecessary to downshift manually to avoid engine lugging. 53 Maintenance challenges in the 6.7-liter engine Issue 59 (6.7 HPCR) Although Chrysler engineers are gradually improving under-the-hood access, basic service tasks are still unnecessarily awkward, particularly fuel and oil filters, and oil pan plugs, says the editor. 42–43 Make-over, salvage and rebuilding of an abused Turbo Diesel Issue 59 (Letter Exchange) Partners at Triple D Performance surprise a customer with a complete make-over of his Turbo Diesel pickup after it had been derelict for two years and scavenged of parts, to produce an impeccable vehicle. 7 Map, Turbocharger compressor, how to read and interpret Issue 58 (Back In The Saddle) At Scott Dalgleish’s behest, Tom Spichtig explains the numbers in interpreting the “map” of a turbocharger-compressor during its installation and testing at Turbo Re-Source. 115 Marketing strategies. See Truck industry and the competitive market; See also Turbo Diesel Chassis Cab and ‘07.5 pickup. marketing strategy May Madness 2007 Issue 57 (Letter Exchange) A California member writes about May Madness 2007, what he learned, enjoyed, and appreciated in his attendance of the event. 7 Issue 57 (Polly’s Pickup) Polly Holmes reports on the 2007 May Madness event, with acknowledgment of TDR seminars, vendors’ presentations, safety and rescue classes, the Pot Luck supper, and general socializing. 107–109 Issue 57 (Life’s A Beach) Jerry Nielsen expresses personal appreciation of the staff at May Madness 2007, bestows accolades, and for next year’s event solicits suggestions he promises to pass on to the proper folks. 110 Issue 57 (Have Ram, Will Travel) Joe Donnelly reports results in major competitions at May Madness 2007; describes seminars, presentations, and social events; and recognizes standout attendees, stars and volunteers. 120–128 McBride, Dave, memorial Issue 57 (Idle Clatter) Jim Anderson notes the passing of Dave McBride, his “friend and teacher of all things diesel,” and co-host of “Two Guy’s Garage.” 82 Mega Cab, conversion to long-bed Issue 57 (Ranch Dressing) John Holmes provides a photo of a Mega Cab Turbo Diesel pickup stretched to accommodate a standard long-bed dually box by Kadell Suggs of Elm Mott, Texas. 103 Issue 57 (Your Story) TDR spotlights Central Texas Frame & Alignment which is building and marketing an extended-frame, long-bed extension for the Mega Cab dually. 141 Issue 58 (Your Story) Editor Patton proudly recounts conversion of his ‘07.5 3500 Mega Cab Turbo Diesel to a long-bed box, and provides names and addresses of sources and fabricators. 143 Issue 59 (Letter Exchange) Jon Exun submits a photo and description of the long-bed converson of his ‘07 Mega Cab, Laramie, 5.9, 4 x 4 Turbo Diesel, performed by Kadell Suggs of Central Texas Frame and Alignment. 8 Issue 59 (Your Story) Robert Patton describes conversion of his’07.5 Mega Cab 3500 from short bed to long bed, in a narrative including its original inspiration, acquisition of an exchange bed, journey to the fabricator, assembly, results, with photos. 116–119 Membership decal Issue 60 (Tailgating) The editor notes the inclusion of the annual free membership decal, mailed inside the magazine’s coverwrap. 4 Methanol injection, cooler kit Issue 57 (Product Showcase) Snow Performance promotes a boost cooler kit for methanol/water injection, designed to increase horsepower and torque while lowering EGT. 158 Midwest Military, antique military vehicle parts Issue 60 (Miscellaneous Ramblings) Don Bunn recounts the career of John Bizal, from his first military truck at age 16, developing into a major supplier of collector military vehicle parts, catering to WWII and Korean era Dodge-built vehicles. 136–137 Mud flaps, aftermarket. See also Accessories, added by the editor to his new Mega Cab Issue 57 (Back In The Saddle) Scott Dalgleish notes the need for mud flaps, particularly on unpaved rural roads, and selects the DuraFlap, a product he evaluates as being of superior material, workmanship, and performance. 118 Issue 58 (Member2Member) Bill Stockard identifies Mopar mud flaps as essential add-ons to any new truck he would buy. 11 Mystery switch, provoking the “Check Engine” light Issue 59 (24-Valve Engines) Readers discover that installing a 40- or 50-ohm resistor will prevent the “Check Engine” light from flashing inappropriately, after installation of the mystery switch in California specification trucks. 35 Nardelli, Bob, assessing Chrysler’s new CEO Issue 58 (Blowin’ In The Wind) The editor samples media opinion about election of Bob Nardelli by new owner Cerberus to serve as Group Chairman and Chrysler CEO. 56 Noise, squeaking in windshield mount Issue 60 (5.9 HPCR) A chirping sound in the dash area is identified as originating in a rubbing of the windshield’s rubber grommet in its metal mount. 38 Noise and vibration, reduced in the 6.7-liter engine Issue 57 (6.7 HPCR) Joe Donnelly notes that Cummins has responded to Dodge’s request for a quieter power plant and describes design and manufacture refinements in the 6.7-liter engine which reduce both noise and vibration. 55 Noises, various. See the following topic heads: Exhaust noise, reducing; Engine tapping noise, troubleshooting; FASS fuel pump, noise reduced in new models; 62 www.turbodieselregister.com TDR 61 Fuel control actuator (FCA), explained; Fuel injector, troubleshooting; Fuel lift pump, source of ticking noise; Heater, Ventilation, and Air Conditioning (HVAC), noise and vibration; Noise and vibration, reduced in the 6.7-liter engine; Noise, squeaking in windshield mount Rack-and-pinion steering unit, noisy; Radiator cap seepage and noise at; Sound level, in-cab, ‘06 vs. ‘07 models; Ticking sound in engine bay North American International Auto Show (NAIAS) Issue 60 (Four Whaling) G. R. Whale recalls his interests at the 2008 Detroit NAIAS, the Kia Borrego SUV and the Audi R8 diesel; anticipates Acura’s 2009 diesel; and laments the industry’s penchant for me-too-ism and playing it safe. 63–64 Odometer, repair of Issue 57 (First Generation) Readers identify source for odometer gauge-cluster replacement parts for First Generation truck and describe technique for safely removing delicate speedometer needle. 24 Off-road diesel, uncertain status under EPA rules. See Performance enhanced diesels, EPA status uncertain Off-road driving, improving quality of ride. See Suspension, aftermarket, to improve off-road performance Offset, in wheel measurement. See Wheel, measuring and calculating offset and backspace Oil-in-coolant discharge from engine, troubleshooting Issue 60 (First Generation) A suspicious discharge of an oil-coolant mix is traced to a failed oil cooler, requiring replacement of the unit. 18 Oil change interval, as signaled by EVIC diagnostic code, evaluating usefulness of Issue 60 (6.7 HPCR) Readers compare findings on usefulness of oil-change alerts from EVIC digital monitoring. 44 Oil change interval for 6.7-liter engines Issue 58 (Backfire) Responding to a reader’s challenge of the oil change interval for the ‘07 Chassis Cab reported in Issue 57, p. 61, the editor admits confusion and refers to the Owner’s Manual as the ultimate authority. 152 Issue 59 (6.7 HPCR) Joe Donnelly emphasizes that best protection for 6.7-liter engines is complying with terms of warranty, which specifies oil change every 2000-3000 miles, justified because additive life is short and key to effective lubrication. 41 Oil change light, interval calculation by algorithm Issue 59 (6.7 HPCR) The interval automatically calculated before the dash light signals need for a change is determined by an algorithm based on elapsed time, temperature, load, and idle time. 41 Oil in fuel, troubleshooting Issue 60 (6.7 HPCR) Readers deliberate on the danger level of oil contamination detected in lab analysis of fuel, its diagnostic significance, and its relation to oil-change interval in 6.7-liter engines. 46 Oil leak, driver’s-side engine-wall, troubleshooting Issue 60 (24-Valve Engines) Readers identify the tappet or side-cover gasket, the oil-pan bolts, or the rear main oil seal, as possible sites for a copious oil leak fouling the engine wall on the driver’s side, in a 24-valve engine. 28 Oil pan, replacement with stock or aftermarket Issue 59 (5.9 HPCR) There is no aftermarket oil pan for the Third Generation truck, but a new stock replacement, specific to engine model, could have oil control baffles installed to provide consistent oil pressure and subdue oil agitation. 36 Oil pan and differential covers, aftermarket upgrade to increase pulling efficiency. See RV haul trucks, beefing up your old rig to pull a heavier load Oil pressure sending unit, hex socket for removing Issue 59 (5.9 HPCR) Removal of the oil pressure sending unit on a ‘06 Turbo Diesel requires a deep 1-1/16” socket. 37 Oil pressure sending unit, matching parts to old three-pin units Issue 58 (24-Valve Engines) TDR readers work together to solve the problem of superseded parts numbers in replacing the oil-pressure sending unit of the 24-valve engine. 30 Oklahoma Governor’s Leadership in Manufacturing Award Issue 58 (TDReview) In a press release, Blumenthal Companies of Oklahoma City, remanufacturer of Mopar manual transmissions, proudly announces its receipt of the Oklahoma Governor’s Leadership in Manufacturing Award. 157 Overdrive failure, troubleshooting. See Fuse failure, cause of multiple function failures Overheating in First Generation engine under load Issue 59 (First Generation) To address low power and overheating under load in a newly purchased First Generation truck, the operator is advised to flush the cooling system, check valve adjustment, upgrade intake side of turbocharger, and buy gauges. 22 Pacbrake PRXB, installation instructions Issue 60 (5.9 HPCR) Doug Leno selects the Pacbrake PRXB for compatibility with ATS’s Aurora 5000-based compound turbos and Arcflow air intake in his ‘04 truck, and describes its installation, with full instructions and illustrations. 34–36 Painless Wiring Kit Issue 58 (Member2Member) Bill Stockard endorses the Painless Wiring Kit to eliminate the rat’s nest of wiring behind the dash. 10 Particulate filter, regeneration explained Issue 59 (Celebrity Corner) Sam Memmolo explains the principle of the particulate filter on newer model Turbo Diesels, and describes how the process of regeneration works. 84–85 Parts, discontinued, sourcing. See Dodge pickups, finding parts discontinued by manufacturer Performance enhanced diesels, EPA status uncertain Issue 60 (Technical Topics) Cummins has EPA certification only for “on-highway” vehicles, with no EPA provision for “performance only,” putting TDR off-roaders and racers outside the rules, a quandary as regulation becomes more strict. 50–52 Performance enhancement product. See entries under Power enhancement Piston rings, replacing, procedure Issue 59 (Member2Member) Joe Donnelly advises a reader that piston rings cannot be replaced without removing the engine, and gives reasons, instructions, and advice. 16 TDResource . . . . Continued Pistons, replacements in re-building a 12-valve Turbo Diesel Issue 60 (12-Valve Engines) For re-building a 12-valve engine, Joe Donnelly provides advice on selecting the better pistons in a vehicle intended primarily for street use, and in a vehicle designed for both decent street performance and enhanced power. 22 Power, deficient in First Generation truck under load. See Overheating in First Generation engine under load Power enhancement. See also entries under headings at Performance enhancement Power enhancement, adding multiple products Issue 57 (5.9 HPCR) John Janko indulges in a little so-called “Coffee-Table/Internet Engineering” and describes installation of TST’s Super Phat Shaft 62/14 turbocharger and PowerMax CR module, with an ATS two-piece manifold to match. 50–51 Issue 57 (Idle Clatter) In a survey of mistakes made in “Coffee-Table Engineering,” Jim Anderson advises that upgrades of injectors and turbochargers should be designed and tested for compatibility. 76 Issue 57 (Product Showcase) Richard Holdener gains 201 hp by “multi-layering” three powerenhancement products: the Power Puck from Diablo Sport, the Boost Cooler from Snow Performance, and the Predator from Diablo, at a cost of $1495. 156–159 Power enhancement, modifying injector nozzle. See Fuel injector nozzle, machine modification of Power enhancement, some useful accessory additions Issue 60 (5.9 HPCR) To a reader with a general question of how he might increase power in a recently purchased ‘03, Joe Donnelly suggests the TST Powermax-CR and the Smarty, both of which he says offer good value. 36 Power enhancement in a vehicle modified for ultimate speed. See Demonstration truck, modified for ultimate power and speed Power enhancement product: digital tuner and/or monitor Issue 57 (TDRelease) The VanAken SmartBox, for models ‘03–’06, permits adjustment of fuel pulse width and pressure and injection timing; with added capacity to boost pressure on the ‘04.5-up models with electronically regulated boost. 160 Issue 57 (TDRelease) TS Performance announces the PowerPlay MP-8 for the 6.7-liter DodgeCummins engine, a monitor that displays readings on the windshield. 162 Issue 58 (TDRelease) Edge Products announces availability of its “Juice with Attitude” monitor and tuner for the ‘07.5 and newer Cummins 6.7-liter engine. 156 Issue 59 (TDRelease) Superchips presents a programmer designed for higher horsepower in the 6.7-liter Turbo Diesel engine. 135 Issue 59 (TDRelease) In the tradition of its Smarty tuner, Bob Wagner and Associates announce availability of the versatile but most modest Smarty Junior. 136 Power enhancement products, general Issue 58 (Member2Member) Joe Donnelly surveys guidelines, constraints, and thresholds in a rational program of adding accessories and upgrading components in the quest for increased power and performance in late model Turbo Diesel trucks. 8 Issue 58 (From The Shop Floor) Andy Redmond provides a quick and useful overview of power enhancement accessories for Second and Third Generation Turbo Diesels. 149 Power enhancement vs. drivability Issue 59 (Have Ram, Will Travel) Joe Donnelly leads readers through salient parameters in assembling products in an integrated power enhancement system for the Turbo Diesel engine, emphasizing careful tuning and testing of every modification. 94–96 Power for towing, perceived as insufficient Issue 59 (TDRV) Jim Anderson explains the limitations of drive train components, whether stock or upgrade, which determine towing power, and considers available ways to increase performance. 111–112 Power increase and fuel efficiency, achieving both Issue 60 (Have Ram, Will Travel) For readers seeking both to increase power and to maintain the best compromise in fuel efficiency, Joe Donnelly recapitulates his earlier articles of greatest relevance to both, providing a general overview. 90 Power steering fluid, leak, repair of Issue 58 (5.9 HPCR) Part numbers and instructions for replacing the O-ring between the pump and reservoir of the power-steering system are provided by a TDR reader to fix a fluid leak. 38 Power steering reservoir, O-ring, repair of Issue 58 (5.9 HPCR) A TDR member provides parts numbers and instructions for inexpensively replacing the O-ring between the power-steering pump and reservoir. 38 Press, Jim: media applauds his selection for President and Vice Chairman of Chrysler Issue 58 (Blowin’ In The Wind) Automotive News magazine applauds Cerberus’ selection of Jim Press for Vice Chairman and President of Chrysler, as a “big talent” lured from Toyota. 58 Propane price increase Issue 58 (TDRV) Of particular interest to RVers, propane prices are steadily rising, which Jim Anderson says is unjustified profiteering, about which little can be done by individual owners, other than taking all reasonable steps to conserve energy. 160–161 Psychological control over the unforeseen, character patterns Issue 59 (Motor-Minded) Dr. Mark Barnes reflects on the psychological perspective known professionally as “Locus of Control,” the propensity in individuals to be either doggedly determined or more relaxed in persevering in unforeseen vicissitudes. 62–63 Pyrometer. See Gauges, auxiliary Pyrometer sensor probe, preferred location Issue 60 (5.9 HPCR) Joe Donnelly says that the better place to drill for locating the pyrometer probe is pre-turbo rather than post-turbo, and gives instructions for doing a clean job. 38 Rack-and-pinion steering unit, noisy, problematic Issue 58 (Idle Clatter) Jim Anderson’s suspicions are aroused by two rack-and-pinion steering units installed in his ‘06 Turbo Diesel, suggesting possible problems originating with the original supplier. 62 Radiator, fouled by spume from blow-by bottle Issue 58 (24-Valve Engines) Oil spume from the engine blow-by bottle tends to clog the radiator grid, increasing the need for periodic servicing. 34 Radiator, servicing Issue 57 (24-Valve Engines) TDR members and the editor remind readers to thoroughly clean the outside of the engine radiator periodically. 38 Issue 58 (24-Valve Engines) Several readers compare experience and observation; and emphasize the need for periodic cleaning of the radiator, which on the Turbo Diesel requires its removal. 34 Radiator and intercooler protective mesh shield Issue 57 (Idle Clatter) Jim Anderson advises shielding the radiator and intercooler with a piece of nylon mesh screen, cut to fit and secured by wire ties to protect from clogging by bugs and damage from stones. 78 Radiator cap seepage and noise at Issue 59 (5.9 HPCR) Several TDR members find in early use of a new truck the radiator cap emits a growling noise, seeps coolant, and stains around the orifice, corrected by a zip-tie or a small screw-type hose-clamp, described in TDR Issue 46, p. 42. 37 Radio, stereo, JVC brand. See Accessories, added by the editor to his new Mega Cab Radio speakers, re-installing of Issue 58 (First Generation) In First Generation trucks, radio speakers installed in doors are riveted or screwed in place, and yield to gentle prying. 16 Rattling noise during acceleration. See Fuel control actuator (FCA), explained Rear-end shudder, at launch under load Issue 58 (6.7 HPCR) Rear-end hopping and shuddering at low startup speeds under a load is not a new problem, according to a member, who provides analysis, a kit number, and instructions for a fix. 44 Rear-view camera, V3P brand. See Accessories, added by the editor to his new Mega Cab Rear axles, Dana 70, order of assembly Issue 57 (Backfire) Andy Redmond specifies the steps in dis-assembling and re-assembling the Dana 70 axle on each of the First- and Second-Generation Turbo Diesel trucks. 154 Recalls. See Turbo Diesel 6.7-liter vehicles, emissions recall Red Hat Society, Polly Holmes issues a call to organize Issue 57 (Polly’s Pickup) Polly Holmes proposes organizing a TDR chapter of “The Red Hat Society,” a national organization of mature women who meet for tea wearing red hats and purple dresses, to convene at TDR events and have a good time. 106 Red light, blinking under the dash, explained. See Batteries, recharging Refueling tank, 50-gallon, aftermarket Issue 58 (TDRelease) Transfer Flow, Inc., introduces a 50-gallon refueling tank for all late model trucks, made of aluminized steel, baffled, in a notched design situating the pump below the height of the tank. 157 Resale value of diesel pickups, in a negative market Issue 60 (Idle Clatter) Jim Anderson warns readers that with rising fuel costs the resale value of their diesel truck is falling, and suggests that possibly one way to save money is to move accessories and upgrades from the old to a new truck. 67 Roof rack, aftermarket Issue 57 (TDRelease) Flying M Enterprises, of Cumming, GA, has developed a heavy-duty steel roof rack, the Mule, for late-model extended-cab or four-door Turbo Diesel pickups. 163 Rough running. See Fuel control actuator (FCA), cause of poor drivability RPM runaway, troubleshooting for possible engine damage Issue 57 (12-Valve Engines) Joe Donnelly identifies the kinds of engine damage that may result from rpm runaway, and tells how to check for damaged valves and camshaft gear. 32 Running boards, AMP Research. See Accessories, added by the editor to his new Mega Cab RV, medium-duty towing vehicles Issue 58 (Ranch Dressing) Addressing the demand for larger tow vehicles to haul increasingly heavy RVs, John Holmes provides the relevant specs on the ‘08 4500/5500 Turbo Diesel Class 4 & 5 trucks. 106 RV, removing decals from Issue 59 (TDRV) Readers compare ways to remove decals from their RV exteriors, using products including citrus paint remover, alcohol, lighter fluid, naphtha, 3M adhesive remover, and other solvents. 114 RV, removing stains from fabric and fascia Issue 59 (TDRV) Drawing on years of RV experience, Jim Anderson shares hints for removing stains from RV carpets and upholstery, and water spots from fiberglass. 113 RV brakes, converting from drum to disc Issue 59 (TDRV) Converting RV brakes from drum to disc is weighed by half a dozen correspondents who speculate that the significant improvement in performance and safety may well be worth the hefty cost, more than $2000. 113 Issue 59 (TDRelease) EGR Brakes, of Statesville, NC, describes their bolt-on disc brake conversion kit, complete with rotors, calipers, pads, pump, steel line, reverse valve solenoid, and Prodigy Controller harness adapter, for all types of trailers. 136 RV electrical-circuit surge-protector. See Electrical circuit surge protector, RV application RV haul trucks, beefing up your old rig to pull a heavier load Issue 60 (Ranch Dressing) For those replacing their old trailers with heavier RVs, John Holmes suggests aftermarket transmission and differential pans to increase lube capacity in their Turbo Diesel trucks. 72–73 RV industry, sales status report Issue 58 (TDRV) Because of high fuel prices and a slowing economy, sales of RVs are down and manufacturers are retrenching, in what Jim Anderson calls a buyer’s market. 160 RV manufacture, quality issues Issue 57 (TDRV) A group calling itself RV Owners Advisory Council claims to be a voice of consumer concerns about product quality, but, because of ties to the industry, may not be a disinterested advocate, says Jim Anderson. 148 RV property inventory and record keeping Issue 59 (TDRV) Jim Anderson advises preparing a packet of essential personal documents, records, and legal papers, for quick retrieval in emergencies on the road, a kit he calls his “Jumpbox.” 110–111 Issue 59 (TDRV) Citing probems with insurance adjustors in cases where RVs have burned or been destroyed, Polly Holmes recommends making a complete inventory of contents from stem to stern: furniture, tools, personal items, accessories. 112 Issue 60 (Letter Exchange) A reader tells how he uses video tape and camcorder to inventory and record data on property in his RV, garage, and home. 6 Issue 60 (Polly’s Pickup) Polly Holmes again encourages travelers in RVs to make careful inventories of the vehicle contents, personal property, and legal papers to deal effectively with the possible consequences of accident, theft, or fire. 77–78 TDR 61 www.turbodieselregister.com 63 TDResource . . . . Continued RV rallies Issue 58 (TDRV) Polly Holmes reports on the Good Sam RV Rally 2007, Redmond OR, with a review of “Highway Health Care” conducted by an R.N.; and two RV tire seminars, one by Goodyear and one by Michelin. 161–163 RV shows. See Tampa RV show RV tires, calculating service life. See Tires, RV RV tires, problems attendant to prolonged storage. See Tires, RV RV touring, routes, sites, and sights Issue 58 (TDRV) Members with experience in the areas describe destinations and routes suitable for slide-in RVs and small trailers in the Moab area and the San Rafael Swell backcountry of Utah. 164 RV trailer, quality problem Issue 58 (TDRV) Jim Anderson explains that excessive “dishing” and flexing of the skin on the prow of a travel trailer at high highway speeds results from lack of adequate reinforcement under the cap, a consequence of poor design and manufacture quality. 160 RV travel to Alaska. See Alaska RV travel RV travel trailer, suspension failures, troubleshooting Issue 58 (TDRV) A member with several hundred thousand miles experience hauling travel trailers chronicles his suspension failures, and presents precautionary and troubleshooting measures. 161 RV upgrades of equipment and accessories Issue 58 (Have Ram, Will Travel) Joe Donnelly recommends a book titled “The RV Upgrade Handbook” by Jay Bennett, a useful resource for RV owners intent on the best performance from their rigs. 124 Seat covers, Cover Craft brand. See Accessories, added by the editor to his new Mega Cab Seat covers, Seat Savers brand Issue 58 (Ranch Dressing) John Holmes describes and endorses “Seat Savers” seat covers, provided with convenient pockets, available in seven colors, from Geno’s Garage. 107 Seat heater, Rostra brand. See Accessories, added by the editor to his new Mega Cab Seat heater and vibrator, installation of Issue 60 (Member2Member) The editor describes “easy surgery” on the cab seat and provides illustrations for do-it-yourself installation of a Check brand seat heater and back vibrator in his ‘07.5 Turbo Diesel truck. 8–9 Seat position, modifying factory settings. See Accessory installation, in-cab, savvy advice for simplifying the job Sebring International Raceway, 2007 annual race Issue 60 (Idle Clatter) Jim Anderson visits Sebring International Raceway, in south-central Florida, site of world famous 12-hour endurance competition, and watches racers run test laps. 67 Self-image, reflected and aggrandized in material possessions Issue 58 (Motor-Minded) TDR “house psychologist” Dr. Mark Barnes discourses on self-image as it is reflected and sometimes distorted in material possessions, including pickups. 142 SEMA 2007 (Specialty Equipment Marketing Association), annual show Issue 59 (Ranch Dressing) John Holmes reports his observations of SEMA 2007, focusing on product displays of diesel interest, as well as social meetings there with associates from TDR and other friends. 68 Issue 59 (Have Ram, Will Travel) Joe Donnelly peruses the 2007 SEMA show, concentrating on the booths of advertisers in the TDR. 93 Serpentine belt, replacement of Issue 57 (24-Valve Engines) One member advises another that 70,000 miles marks a good time to replace the serpentine belt. 39 Issue 57 (5.9 HPCR) Eight members and the editor each reports his regular order of steps in removing and replacing the serpentine belt, a complex but rational operation when done systematically. 41 Service facilities, checking of, for possibly negligent work by Issue 57 (Idle Clatter) Jim Anderson tells of a service facility that neglected to fill fluid in a new transmission, with dire results, and advises immediate attention to any sign of trouble after mechanical work. 80 Service facilities, recommended Issue 57 (Idle Clatter) Jim Anderson reports good service from Jeff Smith Chrysler of Perry, GA, and recommends it for quick and accommodating attention to travellers on the road. 78 Issue 58 (Letter Exchange) A reader on an extended RV tour seeking a shop willing to service his Turbo Diesel using his oil and filter praises Midwest Diesel Performance for doing the job at a nominal charge. 6 Issue 58 (Letter Exchange) A reader who had improvised installation of a Pinnacle Power exhaust system on his ‘92-model Turbo Diesel, commends the manufacturer for its gratuitous re-installation when he dropped by the factory on a tour of the Tetons. 6 Issue 59 (Letter Exchange) A correspondent praises work performed by Standard Transmission, a TDR advertiser, reporting fair and good service. 6 Service manual, 24-valve engine, recommended Issue 59 (24-Valve Engines) TDR readers agree that the best available service manual for the 24valve engine is the one published by Dodge, available in print and CD versions. 34 Service manual, errors noted and corrected Issue 57 (Member2Member) An alert TDR reader identifies errors in the service manual for Second-Generation trucks with 24-valve engines, and provides corrected information on procedures and tools. 15 Shackle bushing. See Suspension, front end shackle bushing, replacing Shift control electronics, override of Issue 60 (TDRelease) To override the vehicle’s computer control and give the operator elective control over transmission shifting in towing applications, TS Performance makes a plugand-play Shift Master control unit, to minimize engine hunt and flares. 146 Shimmy and shake in front end, diagnosing Issue 58 (First Generation) Possible causes of violent front-end shimmy and shake are identified with suggestions for repair, by several TDR readers. 16 Shock absorbers, aftermarket Issue 58 (Member2Member) Bill Stockard explains why he prefers the Rancho RS9000X 9-way adjustable shock absorbers on his rig loaded with a slide-in camper. 10 64 www.turbodieselregister.com TDR 61 Shut-down solenoid failure, troubleshooting. See Fuse failure, cause of multiple function failures Signal/blinker lights, combination flasher unit Issue 60 (24-Valve Engines) One member tells another the part number for the Trico combination brake-light/turn and hazard flasher, and its location in the junction box of the 24-valve engine. 26 Silver State Classic road rally Issue 59 (Life’s A Beach) Jerry Nielsen narrates his exploits as navigator to Brad Ekstam driving a ‘05 one-ton, long-bed, 4x4 Quad Cab, the only diesel at the Silver State Classic road race in Ely, NV, racking up a respectable average 133 mph. 76–82 Sirius radio, instructions for remounting antenna Issue 60 (TDRV) When adding a slide-in truck camper to Turbo Diesel trucks factory-equipped with the Sirius radio, before getting a proper signal it is necessary to relocate the antenna, either with a replacement from Sirius or a magnetic mount. 130 Six-Bay fuse panel. See Accessories, added by the editor to his new Mega Cab Snowbird get-together in Florida, proposal Issue 57 (Idle Clatter) Jim Anderson projects a possible winter meet in central Florida for Snowbirds with a TDR connection, and solicits interested responses. 76 Issue 58 (Idle Clatter) Jim Anderson, who regularly takes his trailer to Central Florida in the winter, proposes scheduling a get-together of like-minded Snowbirds. 62 Sound level, in-cab, ’06 vs. ’07 models Issue 59 (6.7 HPCR) The editor performs tests to compare the decibel levels within the cab during engine operation of the ‘06 5.9-liter model and the ’07.5 6.7-liter model, to find that the latter is significantly quieter, with figures to prove it. 44 Speedometer malfunction, troubleshooting Issue 58 (24-Valve Engines) Malfunction in the speedometer is traced to a defective speed sensor/antilock-brake sensor on the rear axle of the 24-valve Turbo Diesel. 34 Speedometer failure, troubleshooting. See Fuse failure, cause of multiple function failures Speedometer sensor, installation at transmission/transfer case Issue 57 (First Generation) A TDR reader provides instructions for proper attachment of the speedometer sensor to the side of the transmission/transfer case on a First Generation truck. 24 Starter solenoid, failure, troubleshooting Issue 57 (First Generation) Replacing the brushes in the starter motor fixed an apparently defunct starter solenoid in a First Generation truck. 26 Startup in cold weather. See Cold-weather engine starting, guide to Startup problems, troubleshooting. See also Engine priming, troubleshooting failure in Issue 58 (First Generation) Readers identify broken ignition switch as the cause of a First Generation engine’s failure to start. 17 Issue 59 (5.9 HPCR) A reader whose truck starts but then stalls in two seconds after damaging his fuel control actuator (FCA) is advised by Joe Donnelly to get a new FCA for his CP3 pump. 38 Step bar, aftermarket Issue 58 (Member2Member) Although it is no longer available, Doug Leno gives high marks to MAAP Tube Step bars, especially since he lifted his suspension. 12 Steps, truck-bed entry, retractable Issue 59 (Ranch Dressing) John Holmes describes Amp Research’s BedStep retractable step and its installation, which was one of the quickest in his experience for accessories. 65 Stretch conversions, extending chassis and body, custom Issue 57 (Miscellaneous Ramblings) Don Bunn visits Bayer Auto Company, specialists in custom stretching of chassis and bodies of Dodge and other trucks to accommodate extra seats and doors or a third axle. 144 Super-single wheels and tires, displacing duallies Issue 57 (Idle Clatter) Jim Anderson notes that increasingly duallies are being displaced by “super-single” systems, in which each super-single tire is as wide as a set of duals and provides a smoother ride, better fuel mileage, and longer tire life. 80 Surge protector. See Electrical circuit surge protector, RV application Suspension, aftermarket, to improve off-road performance Issue 57 (Member2Member) To improve the off-road ride of his ‘04 4x4 3500 Turbo Diesel, Doug Leno upgrades to the Kore Chase suspension, and explains his reasons, the process, and results. 10–14 Suspension, front-end components, replacement Issue 59 (12-Valve Engines) Members pool experience and advice in replacing front-end components and parts, recommending polyurethane bushings in place of rubber. 26 Suspension, front end, troubleshooting Issue 58 (First Generation) Readers address the problem of shimmy in the front end of a First Generation truck. 16 Suspension, front end shackle bushing, replacing Issue 57 (First Generation) A reader provides part number for the front spring shackle bushing on First Generation trucks, the same bushing used for control arm pivots. 28 Suspension enhancement systems, Timbren kit vs. air bags Issue 57 (Member2Member) On his Turbo Diesel rigged for a camper slide-in, Bill Stockard installed the Timbren suspension enhancement kit, to evaluate it as a replacement for air bags, reporting satisfactory performance. 16–18 Suspension kits, aftermarket Issue 58 (From The Shop Floor) Andy Redmond weighs the respective merits of Timbren rubber springs and Air Lift air bags. 148–149 Sway-bar end links, aftermarket Issue 58 (TDRelease) Suspension MAXX releases a press story describing its heavy duty sway bar end links, claiming longer-lasting and superior performance. 156 Issue 60 (Member2Member) The ball-in-socket end links to OEM sway bars on older Turbo Diesel trucks are liable to failure, according to a spokesman for Suspension Maxx Inc., which sells a heavy-duty unit with high-durometer polyurethane bushings. 13 Tachometer, installation of, instructions Issue 57 (First Generation) A TDR reader provides the wire color code for the factory built-in tachometer connector plug on a First Generation truck; and also provides information on an adaptor from ISSPRO. 26 Tachometer failure, troubleshooting. See Fuse failure, cause of multiple function failures TDResource . . . . Continued Tailgate drop support, WigiDigit GateGlide. See Accessories, added by the editor to his new Mega Cab Tampa RV show Issue 60 (TDRV) Jim Anderson reviews the 2007 Tampa RV Show, noting improvement in quality; increase in prices; more elaborate toyhaulers; the incredibly luxurious and expensive Kountry Aire; and the continuing dominance of Lance among slide-ins. 132–133 TDR annual wall calendar Issue 58 (Tailgating) The editor reports on the impressive number and quality of truck photographs submitted for the 2008 TDR wall calendar, distributed with issue 58, as well as some amusing and curious pix that didn’t make the cut. 4 TDR clubs and chapters Issue 57 (Chapter News) The roster of TDR chapters is brought up to date. 130 Issue 58 (Chapter News) The roster of TDR chapters is brought up to date. 126 Issue 59 (Chapter News) The roster of TDR chapters is brought up to date. 100 Issue 59 (Chapter News) The South Carolina TDR (SCTDR) chapter held an inaugural meeting and dyno runs at Perfection Clutch, Timmonsville, SC, Sept. 22, ‘07. 101 Issue 60 (Chapter News) Quarterly news as well as the roster of TDR chapters is brought up to date. 100 TDR emblems, plates, and tags Issue 58 (TDR/R/R) The editor describes TDR emblems, decals, and nameplates to identify membership or high mileage. 133–136 Issue 59 (TDR/R/R) The TDR names members receiving high-mileage tags. 106–107 Issue 60 (TDR/R/R) The editor states the qualifications for TDR’s emblems, decals, and nameplates to identify membership, high mileage, and other records; and publishes the names of designees in the current quarter. 109–112 TDR magazine format and appearance Issue 60 (Tailgating) The editor announces that the TDR is now printed entirely in color, on lighter-weight paper stock, producing a handsomer magazine, and one better able to cope with rising postal rates per ounce. 4 TDR readers’ testimonials about the magazine Issue 58 (Letter Exchange) A reader cites the magazine for valuable information on Turbo Diesel know-how and accessories, and tells of his adaptation of products he learned of in its pages. 6 Issue 58 (Letter Exchange) A subscriber says that the magazine and its members have saved him hundreds of dollars over the years of working on his Turbo Diesel. 6 Issue 60 (24-Valve Engines) Four readers proclaim the high value they place on the TDR as a unique source of information, explanation, and assistance in solving equipment and performance problems, and in improving the operation of their vehicles. 28 TDR readers’ yarns about the Turbo Diesel truck. See also Forbus, Melissa, her story Issue 57 (Letter Exchange) Members of TDR tell their stories testifying to the joys and merits of operating an array of Turbo Diesels and other models of Dodge trucks. 6–8 Issue 58 (Letter Exchange) A member in Sweden tells about his ‘01 Dodge-Cummins Turbo Diesel, its adornment and his pleasures with his rig, named “Black Betty,” second to no other lady in his affections. 7 Issue 59 (Letter Exchange) When stopped for speeding, a reader established rapport with the patrolman by explaining how the Dodge Turbo Diesel’s electronic servo controls adjust safely to road conditions, eliciting only a warning and a chuckle. 6 Issue 60 (Letter Exchange) A reader engaged in farm equipment maintenance and repair tells of the four Dodge trucks he uses in his business and the Turbo Diesels driven by employees. 6 Issue 60 (Letter Exchange) The president of the Northwest Chapter of the American Truck Historical Society tells of hauling exhibits to antique shows with his Dodge-Cummins pickup, and plugs the TDR. 7 TechAuthority Online (replaces TSB directory) Issue 58 (TDReSource) The Dodge TSB (technical service bulletin) directory has been superseded by an online service with information keyed to individual VIN, a powerful resource recommended by the editor. 102 Technical Service Bulletins (TSBs), TDR’s annual review Issue 58 (TDReSource) In its annual review of Dodge Technical Service Bulletins, the TDR presents all relevant releases issued in 2006–2007, to date. 82–101 Theme for Issue 57: “Coffee Table/Internet Engineering”. See also Coffee-Table Engineering, anecdotes and cautions Issue 57 (Tailgating) Robert Patton announces the theme for Issue 57 as “Coffee Table/Internet Engineering” and solicits stories from writers and readers of adventures in free-wheeling accessory add-ons. 4 Theme for Issue 58: Favorite accessories for a new truck. See also Accessories for the Turbo Diesel truck Issue 58 (Tailgating) The editor, owner of a new scarcely-used truck, assigns TDR staff writers who have outfitted new Turbo Diesels since the last magazine roundup on accessories, to report on their present favorites. 4 Theme for Issue 59: “The more things change, the more they stay the same”. See also EPA demands and industry response, constants in the industry Issue 59 (Tailgating) The editor sounds the theme for TDR writers in Issue 59: “The more things change, the more they stay the same”: perennial problems, postures, and patterns of progress in the Turbo Diesel world. 4 Issue 59 (Tailgating) John Janko takes a sweeping view of perennial challenges as well as continuous change in the nineteen-year career of the Dodge-Cummins Turbo Diesel pickup, to show that while some constants persist, there is also much progress. 5 Issue 59 (Back In The Saddle) “The more we get, the more we want, according to Scott Dalgleish, who presents evidence in our everlasting quest for power. 86 Issue 59 (Have Ram, Will Travel) Two overriding constraints when increasing Turbo Diesel power continue to be (1) ever-increasingly severe emissions regulation; and (2) basic physics dictating the turbocharger will invariably be the site of compromise. 94 Issue 59 (Have Ram, Will Travel) In sounding the theme for Issue 59, Joe Donnelly revisits Issue 43, p. 60, where he compared his ’97 and ’04 trucks, to confirm but also to priortize his judgments from a perspective of four more years of operation. 98–99 Theme for Issue 60: “What have you done for me lately?” Issue 60 (Tailgating) The editor sounds the theme for Issue 60: chronicling what writers have done for readers, and what readers have done for TDR. 4 Issue 60 (Idle Clatter) Jim Anderson turns the tables on “what has TDR done for me lately” to read, “what have I, as a member, done for the TDR” and encourages promotion of new membership and subscription to the magazine. 66 Issue 60 (Ranch Dressing) John Holmes, in reflecting on the theme for Issue 60, rhapsodizes over the many benefits member/subscribers to the TDR receive in terms of fellowship, inside information, tech secrets, and new products. 70 Issue 60 (Polly’s Pickup) In addressing the theme assigned to writers in TDR Issue 60, “What have you done for me lately?” Polly Holmes says that the real gift bestowed by the magazine is communion with fantastic people among members and staff. 76 Issue 60 (Life’s A Beach) “What have I done for you lately?” Issue 60’s theme, is a two-way proposition, says Jerry Nielsen, who suggests members should promote the magazine by enlisting new members, even as the magazine unstintingly serves them. 80 Issue 60 (Back In The Saddle) In sounding the theme “What have you done for me?” Scott Dalgleish says that what he has gotten in his relationship with TDR is the boon of sharing with like-minded enthusiasts. 84 Throttle cable, replacement part Issue 60 (First Generation) On a First Generation truck, if the OEM throttle cable is unavailable for replacement, a universal generic cable will do the job and is available from identified aftermarket vendors. 18 Ticking sound in engine bay, troubleshooting Issue 57 (12-Valve Engines) Members troubleshoot a loud ticking sound from the injection-pump side of the engine, including checking for a sticking delivery valve, a plugged filter, and adequate fuel pressure. 34 Timbrens rubber springs. See Suspension kits, aftermarket Timing gear case, instructions for replacing Issue 59 (12-Valve Engines) In response to a member whose killer dowel pin dislodged and broke his timing gear case, Joe Donnelly provides part number, tool list, and full instructions for repair. 32 Timing gear case bolts, potential hazard from loosening Issue 58 (12-Valve Engines) When the gear case cover is removed to make the KDP fix, the five bolts attaching the gear case to the block should be checked for tightness because they present a greater hazard even than a loose dowel pin. 28 Issue 58 (Have Ram, Will Travel) Joe Donnelly says that, besides the notorious “killer dowel pin,” other bolts in the gear case can work loose and cause even more severe damage. 125 Timing gear housing, removal to retrieve alignment key Issue 59 (24-Valve Engines) TDR readers consult among themselves in determining ways to retrieve a line-up key fallen into the timing gear housing during installation of a new injection pump. 35 Timing pin Issue 57 (12-Valve Engines) Joe Donnelly tells how to remove the timing pin, with instructions for fashioning an improvised tool for doing the job. 30 Issue 58 (12-Valve Engines) To a reader with a broken timing pin, Joe Donnelly offers explanation, advice, and instructions for procedure to replace the pin in the 12-valve engine. 26 Tire, trailer, blowout Issue 59 (TDRV) To reduce the likelihood of blowouts, Joe Donnelly recommends loading an RV well below the weight limits, checking the load at each wheel separately, and buying higher-rated tires for extra margin of safety. 115 Tire, upgrade in size and load rating Issue 57 (Member2Member) Doug Leno finds his original BFG 285/70-17 range D tires deficient for his use on the ‘04, 4X4 3500 truck, and describes replacing them with Toyo 35x12.5017 tires, attendant with upgrades in suspension and wheel. 10–14 Tires, RV Issue 58 (TDRV) Polly Holmes reviews essential information on RV tires, detailing specs, service life, maintenance, troubleshooting, and problems, particularly those attendant to deterioration during extended storage. 162–163 Issue 60 (Letter Exchange) A reader reports good performance from a 16-inch LT tire, which he chose over an ST-rated tire (the usual recommendation for trailers) because the latter is available in only a single and unfamiliar brand. 6 Tire size, calculating difference between section width and tread width Issue 57 (Member2Member) In calculating tire size, Doug Leno explains the difference between tire-section width and tire-tread width, in terms of centering and traction. 13–14 Tools, specialty, for the Cummins engine Issue 60 (Have Ram, Will Travel) Specialty tools are practically necessary in working on Turbo Diesels, observes Joe Donnelly, who describes several wrenches helpful in maneuvering in the confines of the engine bay and particularly on the turbocharger. 91 Tool tray, under-hood, Geno’s Garage source. See Accessories, added by the editor to his new Mega Cab Towing power, to increase without sacrificing reliability Issue 59 (TDRV) Jim Anderson explains available performance accessories and upgrades, their limitations and effectiveness, to increase towing power with minimum compromising of reliability. 111–112 Track bar, adjustable, aftermarket Issue 60 (TDRelease) Rare Parts, Inc., of Stockton, CA, introduces a heavy-duty track bar that is larger than OEM, made of billet steel, and adjustable for ‘94–’02 Turbo Diesels. 146 Trailer, weight limits Issue 57 (Idle Clatter) Once again Jim Anderson advises that “doing the math and figuring the weights” is essential before purchasing a trailer to match the towing vehicle. 76 Trailer brake controller, advanced design Issue 58 (Product Showcase) Andy Redmond describes the concept and installation of Brake Smart’s trailer brake controller which features a hydraulic pressure sensor to provide true linear and proportional trailer braking. 154–155 Trailer brake controller, need to adjust for load weight Issue 60 (TDRV) A trailer electric brake controller must be reset for particular load weight each time the load is changed. 128 Trailer hitch. See Fifth-wheel trailer hitch, Reese slider brand Trailer hitch, gooseneck, installing Issue 59 (TDRV) Readers combine detailed information on their several successful selfinstallations of the B&W Turnover all Gooseneck hitch in the beds of Turbo Diesel pickups. 114–115 TDR 61 www.turbodieselregister.com 65 TDResource . . . . Continued Trailer signal light, absence of power at the plug Issue 59 (TDRV) Readers driving late-model Turbo Diesel towing trucks note that absence of power at their trailer signal/brake plugs required a service shop’s resetting the body computer; referenced to relevant technical service bulletin. 114 Trailer wheel bearings, protection against failure Issue 60 (TDRV) To protect against failure in trailer wheel bearings, readers note two necessary precautions: proper periodic lubrication; and monitoring operation within the tolerable temperature range, best checked with hand-held infrared thermometer. 129 Transfer case, electronic, re-engaging after jumping into neutral, procedure Issue 58 (5.9 HPCR) From the Owner’s Manual a reader cites the five steps in shifting an electronic transfer case back into gear after it has slipped into neutral. 37 Transfer case, electronic shifting, spontaneous slipping, troubleshooting Issue 58 (5.9 HPCR) Replacing the shift actuator is the fix for an electronic transfer case that slips into neutral spontaneously and unexpectedly. 37 Transfer pump. See also entries at Fuel lift pump Transmission, 47RE, failure to shift, troubleshooting Issue 60 (24-Valve Engines) Shifting problems in the 47RE transmission may result from malfunction of the governor regulator/pressure switch or the output shaft speed sensor, according to members’ letters, which provide instructions for a fix. 28 Transmission, 48RE, aftermarket rebuild Issue 57 (TDRelease) Level 10 Products offers the high-performance 48RE “Stage 3 Animal” as their best transmission rebuild product offering yet. 162 Transmission, 48RE, fluid leak Issue 57 (5.9 HPCR) A reader identifies and explains the cause of a persistent but minor fluid leak at the front or intermediate band adjustment bolt on the 48RE transmission, and suggests use of sealant. 43 Transmission, 68RFE, user feedback Issue 57 (6.7 HPCR) A member driving a 6.7 HPCR truck is instructed in the method of manual shifting of the 68RFE automatic transmission. 53 Issue 57 (6.7 HPCR) Corresponding members recount their favorable experience in manually controlling the 68RFE automatic while towing heavy loads. 53 Issue 57 (6.7 HPCR) Readers discount report of suspected lugging in operating the 68RFE transmission and report stellar performance. 53 Issue 58 (6.7 HPCR) Members road test the 6.7 HPCR with the 68RFE six-speed automatic transmission pulling a load and describe impressive results in meeting criteria of performance. 42–43 Issue 59 (6.7 HPCR) A reader expresses enthusiasm for the 68RFE transmission and praises his Owner’s Manual for useful information on shifting. 40 Transmission, 68RFE six-speed, questions and answers in “Ask the Engineer” Issue 58 (6.7 HPCR) The editor and Andy Mikonis organize and present answers to wide-ranging questions on the design, specs, operation, and application of the 68RFE automatic transmission, specific to the new 6.7-liter Cummins diesel engine. 46–47 Transmission, automatic, cooler lines, leaking Issue 58 (24-Valve Engines) Vibration, rubbing, and friction from band clamps may cause leaks in metal transmission cooler lines, which might be avoided by substituting reinforced rubber hoses, according to a TDR reader. 32 Transmission, automatic, fluid leak suspected Issue 59 (5.9 HPCR) A reader suspects ATF leak from his 48RE transmission, but is guided through troubleshooting to discover instead a leak of coolant from a hose running beneath the exhaust manifold to the cooler. 38 Transmission, automatic, lapses into neutral Issue 58 (Idle Clatter) Jim Anderson reports that computer reflashes have not corrected his ‘06 truck’s tendency to lapse into neutral, and ponders installing a new valve body. 62 Transmission, automatic fluid, method for total evacuation of Issue 58 (5.9 HPCR) To effect a complete drain of automatic transmission fluid, readers spell out method, and the editor makes reference to back issues with comprehensive instructions. 37 Transmission, G56, performance with 6.7-liter engine Issue 58 (6.7 HPCR) A reader reports good performance from a G56 six-speed manual transmission on a 6.7-liter engine, in pulling loads on grades. 42 Transmission, G56, revised gear ratios in most recent production versions Issue 60 (6.7 HPCR) In the most recent version of the G56 transmission in the 6.7 HPCR truck all gear ratios (with the exception of 5th) are higher (numerically smaller) than in the original G56, according to Scott Dalgleish. 48 Transmission, Getrag, location of vent on First Generation truck Issue 57 (First Generation) A reader locates the vent on the Getrag transmission in a First Generation truck, and describes installing a fitting and hose to prevent oil leak stains. 28 Transmission, Getrag, oil seepage at vent Issue 57 (First Generation) In describing his fashioning of a hose fitting to avoid overflow seepage through the vent of his Getrag transmission, a correspondent suggests to another reader the source of oozing oil in his own rig. 28 Transmission, manual, clutch with power upgrade, performance vs. drivability Issue 58 (5.9 HPCR) Joe Donnelly explains the constraints and functional demands in choosing a South Bend clutch, to balance torque capacity, drivability, and cost. 40 Transmission, manual vs. automatic late-model Turbo Diesels Issue 58 (Idle Clatter) Jim Anderson, in the past a confirmed partisan of the manual transmission, explains why he prefers the automatic to a G-56 for his ‘06 Turbo Diesel. 62 Transmission, NV4500, fifth-gear nut problem. See Fifth gear nut problem Transmission NV5600, level of fluid fill Issue 58 (5.9 HPCR) Joe Donnelly adds fluid to a level 1/4” to 1/2” higher than the bottom of the fill hole in his NV5600 transmission with a fitting he made for that purpose. 39 Transmssion temperature gauge. See Gauges, auxiliary Travel, Alaska. See Alaska RV travel Travel, back country sites suitable for small RVs Issue 58 (TDRV) Member postings on the Web share suggestions for backcountry touring suitable for slide-in trucks and small trailers in the Canyonlands and San Rafael Swell areas of Utah. 164 66 www.turbodieselregister.com TDR 61 Travel and road guidebooks Issue 58 (TDRV) Polly Holmes describes the useful features of “The Ultimate Travelers Exit Guide,” which provides facts on facilities at each exit, listed not state by state but mapped the length of the route; she provides the website of its editor. 161 Issue 60 (Polly’s Pickup) Polly Holmes features travel guidebooks: “The Next Exit,” “The Ultimate Travelers Exit Guide,” “FMCA’s “North American Road Atlas and Travel Guide,” and for impromptu overnight parking “Big Rigs Best Bets.” 76–77 Travel Companion Issue 58 (TDR/R/R) The editor publicizes the TcDR badge awarded to Travel Companions who rescue members on the road, and identifies recipients. 133 Issue 58 (TDR Travel Companion) The editor presents rules, codes, and blank form for enrolling in the TDR Travel Companion on-the-road-assistance directory, and reprints members’ testimonials. 137–140 Issue 59 (Tailgating) The editor commends the readership for the gratifying number of enrollees in the 2008 edition of the TDR Travel Companion, mailed with Issue 59. 4 Travels, by TDR staff Issue 57 (Idle Clatter) Jim Anderson recounts his trailer travel in the Southeast and projects trips to Georgia, North Carolina, West Virginia, Virginia, Maryland, and his annual wintering in Florida. 82 Issue 57 (Polly’s Pickup) Polly Holmes keeps readers up to date on her motor-home travels, most recently to El Capitan, NM, and to her new real estate properties in Texas and Arizona. 106 Issue 58 (Idle Clatter) Jim Anderson chronicles summer RV travels to Tybee Island, GA; Maggie Valley, NC, the country around Cherokee; Roane Moutain, in Tennessee; and a leisurely ramble through historic Virginia. 62–64 Issue 59 (Idle Clatter) Jim Anderson recounts his recent RV travels: daytrips into the Smoky Mountains to escape summer heat; later to Cumming, GA, for talk and society; to Myrtle Beach, SC, for merriment; finally to his winter haven in Florida. 61 Issue 59 (Polly’s Pickup) Polly Holmes’ account of her travels includes trips to Canby, OR, and Taos, NM, as well as to the SEMA show, where she pays particular attention to the Lamborghinis and off-road configurations. 72–74 Issue 60 (Idle Clatter) Jim Anderson recounts his travels from Tennessee to Florida and his adventures along the way, including checking his gas mileage at different road speeds. 67 Issue 60 (Polly’s Pickup) Polly Holmes reports visiting friends in Quartzsite and attending an auto auction in Phoenix in her regular pilgrimage between Nevada and her properties in Arizona and Texas. 77 Issue 60 (Celebrity Corner) Sam Memmolo recounts a trip to Middlebury, IN, for servicing of his Kenworth motorcoach, with details of a catastrophic engine melt-down on the road and subsequent rebuild, followed by a trip to Daytona International. 82–83 Trivia quiz, comprehending TDR’s first 15 years Issue 60 (The Way We Were) G.R.Whale concocts a trivia quiz on facts and ephemera from fifteen years of TDR’s publication, testing readers’ recall of significant and insignificant dates, truck specs, engine arcana, obscure persons, and insider lore. 116–118 Truck bed caps, carpets, liners. See entries under “Bed cap,” “Bed carpet,” “Bed liner” Truck industry and the competitive market. See the following topic heads: Aisin, corporate background; Chrysler Group, operations under Cerberus; Cummins Turbo Diesel engine, unique in the marketplace; Diesel powered vehicles, industry news; Ford, diesel-engine problems in ambulance vehicles; Ford, legal tangle with Navistar’s International Truck and Engine; Turbo Diesel 4500/5500, review Turbo Diesel Chassis Cab and ‘07.5 pickup, marketing strategy Turbocharger, bolt-on, ball bearing, aftermarket Issue 58 (Back In The Saddle) Scott Dalgleish describes in detail the installation by Piers Harry at Tom Spichtig’s Turbo Re-Source of a bolt-on, ball-bearing turbocharger, with performance critique. 114–118 Turbocharger, clogged, troubleshooting Issue 60 (6.7 HPCR) Readers deliberate on ECM codes indicating fouled low-mileage turbos in 6.7 HPCR trucks requiring turbo replacement, possibly indicating poor driving practices and need to perform TSB and upgrade software. 46 Turbocharger, compound, “intercooler,” aftermarket Issue 60 (Have Ram, Will Travel) Joe Donnelly describes the construction, the advantages and the installation of a BD turbo intercooler as replacement for the stock unit, which is efficient only at stock power and sometimes leaks. 92–93 Turbocharger, Holset OEM, compressor Issue 58 (Back In The Saddle) Tom Spichtig, of Turbo Re-Source, evaluates the Holset OEM turbo for the ‘04.5–’07, and pronounces the compressor as problematically sensitive to any “abnormal abuse.” 114 Turbocharger, HX35 stock in Second Generation trucks Issue 59 (Have Ram, Will Travel) Joe Donnelly says that the HX35 turbocharger in Second Generation trucks is entirely adequate in stock configurations, but explains its limitations in any program of significant power enhancement. 94 Turbocharger, installing an ‘04 stock unit on an ‘02 engine, ill-advised Issue 57 (24-Valve Engines) A reader asks if a stock ‘04 turbocharger could be bolted to an ‘02 engine, and Joe Donnelly advises that, while possible, it is not practical, and explains why. 38 Turbocharger, recommendation for an uprated 24-valve Turbo Diesel Issue 58 (24-Valve Engines) Joe Donnelly provides specs of a High Tech turbocharger suitable for an uprated 24-valve Turbo Diesel. 34 Turbocharger, single unit, limitations of Issue 60 (Have Ram, Will Travel) When adding power to Turbo Diesels, it is increasingly difficult to achieve balance between big turbos and small housing, between power and spool-up, as Joe Donnelly explains in advocating BD twin turbos. 94–96 Turbocharger air intake system, pressure test of Issue 58 (24-Valve Engines) TDR readers describe their homemade test adapters to measure the turbocharger air-intake pressure in the Dodge-Cummins engine. 30 TDResource . . . . Continued Turbocharger compressor, calculating the formula of flow vs. presssure Issue 58 (First Generation) Responding to a reader asking how a larger turbo compressor can result in less boost pressure, Joe Donnelly explains the physics and the result. 18 Turbocharger downpipe, aftermarket, for Second Generation Turbo Diesels Issue 57 (TDRelease) ANSA Automotive announces the re-release of its downpipe, to fit ‘94–’02 Dodge Cummins engines upgraded to a larger HX40 turbocharger. 161 Turbocharger downpipe, repair Issue 60 (First Generation) Readers address the problem of a broken attachment collar of the exhaust-side turbo downpipe. 14 Turbocharger drain hose, replacement Issue 60 (First Generation) Readers specify source and part number of the replacement hose and gasket for the steel tube at the bottom of the turbocharger. 14 Turbocharger drain tube, leak at, repair Issue 60 (12-Valve Engines) One reader corrects a leak from the turbo oil drain tube at the block by removing and cleaning the tube and servicing the gasket; and another solves the problem by putting in a new tube. 21 Turbocharger housing, to achieve near-ideal balance of performance parameters Issue 58 (Have Ram, Will Travel) Joe Donnelly says that the new High Tech Turbo 13 sq. cm. housing is near-perfect, in that it “gives about as much as you can get for a moderatesize housing.” 124 Turbochargers, “twin”. See Turbochargers, compound Turbochargers, Aurora 2000 and Aurora 5000, in single configurations Issue 58 (Technical Topics) In his description, analysis, and evaluation of compound turbochargers configuring the ATS Aurora 2000 with the Aurora 5000, Doug Leno reviews the specs, performance, and trade-offs of each when used separately. 48–51 Turbochargers, compound, installation of Issue 58 (Celebrity Corner) On a visit to ATS in Arvada, CO, for a segment of his TV show, Sam Memmolo assists Clint Cannon in installing a twin turbocharger. 112 Turbochargers, compound, addressing the backpressure issue Issue 60 (Have Ram, Will Travel) Joe Donnelly addresses the backpressure issue with twin turbos and reminds the reader that as long as the boost pressure is higher than the backpressure, Delta P is positive and the engine is operating efficiently. 99 Turbochargers, compound, advantages of Issue 58 (Technical Topics) Doug Leno explains and analyses performance data of a compound (“twin”) configuring of the Aurora 2000 and 5000 turbochargers to meld the former’s superior spool-up with the latter’s superiority at higher power levels. 48–51 Issue 60 (Have Ram, Will Travel) Joe Donnelly carefully reasons the problems with using everlarger turbochargers in seeking more power; explains the function and performance of single and of twin turbos; and justifies his enthusiasm for the latter. 94–99 Turbochargers, compound, analysis of Issue 57 (5.9 HPCR) In the injector-nozzle tests reported in this issue, pp. 44-49, Doug Leno’s demonstration vehicle was equipped with twinned “small single” and “large single” Aurora turbochargers, a configuration he will report on in the next issue. 48 Turbo Diesel ‘08 4500/5500, specs for hauling weights Issue 58 (Ranch Dressing) For members with fifth-wheels seeking greater towing capacity, John Holmes provides specs on the new ‘08 Classes 4500/5500 Turbo Diesels. 106 Turbo Diesel, 2500 ‘94, reconditioning of Issue 60 (12-Valve Engines) Joe Donnelly lists the few items likely to need attention by the purchaser of a ‘94 five-speed—including the killer dowel pin issue, shrinking exhaust manifold, and clutch. 22 Turbo Diesel 12-valve pickups, upgrading. See Twelve-valve model of the Turbo Diesel, bringing a “new” used truck up to speed Turbo Diesel 5.9 HPCR, longevity of components, estimating Issue 60 (5.9 HPCR) Joe Donnelly says that with 95,000 miles on his ‘04, he has had no failures in injectors, pump, ball- or U-joints, or transmission; but suggests that a reader with 170,000 miles concerned about longevity be alert to signs of wear. 36 Turbo Diesel 4500/5500 Turbo Diesels, review Issue 59 (6.7 HPCR) Andy Mikonis test-drives the Dodge Ram 4500/5500 Turbo Diesels at their unveiling in October, summarizes his impressions, and reports projected prices and Chrysler’s marketing strategies. 46–47 Turbo Diesel 6.7-liter engine, noise and vibration. See Noise and vibration, reduced in the 6.7-liter engine Turbo Diesel 6.7-liter engine, resume of specs and performance Issue 57 (6.7 HPCR) Joe Donnelly draws on a presentation by Scott Bentz at May Madness 2007 to provide a summary of the features, performance, and status of the new 6.7liter Cummins engines used in the Dodge Chassis Cab and the ‘07.5 pickup trucks. 54–55 Turbo Diesel 6.7-liter engine, use of fuel additives. See Fuel additives, forbidden in the 6.7liter engine Turbo Diesel 6.7-liter vehicles, areas of performance disappointment Issue 58 (Backfire) A reader faults TDR for not addressing problems with the 6.7-liter Turbo Diesel: fuel mileage, regeneration, MIL codes, multiple reflashings; the editor notes Chrysler’s feverish work on the issues, and pledges continuing TDR reports. 153 Issue 59 (6.7 HCR) The editor reports on the disappointment among owners of the 6.7-liter pickups in matters of fuel mileage, regeneration, and snarls in ECU re-flash. 43 Turbo Diesel 6.7-liter vehicles, emissions recall Issue 59 (6.7 HPCR) The editor summarizes Chrysler’s “Emissions Recall G30,” for all ’07.5 and ’08 2500 and 3500 series trucks with the 6.7-liter Cummins engines. 43 Turbo Diesel Chassis Cab and ‘07.5 pickup, marketing strategy Issue 57 (6.7 HPCR) In a summary of information on newly introduced Dodge Turbo Diesel vehicles, Joe Donnelly describes corporate marketing and advertising strategies. 55 Turbo Diesel Chassis Cab, frame construction and dimensions, compared to pickup Issue 58 (6.7 HPCR) Joe Donnelly spells out the difference in construction design and dimensions between the frames of the Chassis Cab and the standard Turbo Diesel pickup. 43 Turbo Diesel engine performance, ‘07.5 vs. ‘06 Issue 59 (TDReview) Jim Anderson test drives the editor’s ‘07.5 Mega Cab dually, with long-bed conversion, to compare its specs and performance with those of his own ‘06 truck; judges it superior, but with one drawback: lower fuel mileage. 48–50 Turn signal lights, troubleshooting. See Brake and turn signal lights, troubleshooting TV receivers, analog to be displaced by digital Issue 57 (TDRV) Jim Anderson warns readers that TV receivers limited to analog signal will be rendered obsolete as of April 17, 2009, by an act of Congress mandating conversion to digital. 148 Twelve-valve engines, parts differences between production versions Issue 60 (12-Valve Engines) The several versions of engines found in Second Generation Turbo Diesel trucks are internally different in several respects: injectors, pumps, piston, camshafts, and timing specifications, unique to each hp rating. 22 Twelve-valve model of the Turbo Diesel, bringing a “new” used truck up to speed Issue 58 (12-Valve Engines) Joe Donnelly identifies three things a new owner of a used 12-valve truck should do first, primarily to protect his investment. 28 Two Guy’s Garage Issue 57 (Idle Clatter) On a TDR writing assignment, Jim Anderson observes the filming of an installment of “Two Guy’s Garage” hosted by Sam Memmolo and Dave McBride in early 2007, with asides on his friendship with the two principals. 84–85 Issue 58 (Celebrity Corner) Sam Memmolo provides an account of activities on the road as he films his TV show, visits ATS where he helped install a twin turbocharger, and attends motor events in Detroit. 112–113 U-joint wear, as cause of driveline vibration Issue 59 (5.9 HPCR) A member identifies problems with U-joint wear as the cause of driveline vibration when towing, corrected by using a torch to remove units resin-glued at the factory, and installing U-joints with clips and superior seal. 36 Ultra Low Sulfur Diesel (ULSD) fuel, model year vehicles requiring it exclusively Issue 58 (Idle Clatter) Jim Anderson reminds readers that use of Ultra Low Sulfur Diesel fuel is a matter of choice except for ‘07.5 or later trucks with 6.7-liter engines, in which it is mandatory. 60 Ultra Low Sulfur Diesel Fuel, vs. Low Sulfur Diesel Fuel, comparative energy efficiency Issue 57 (Idle Clatter) In comparisons that he himself has made, Jim Anderson finds that with ULSD his fuel efficiency is approximately 1 mpg less. 80 Used diesel pickups, value declines. See Resale value of diesel pickups, in a negative market Vacuum pump rebuild, component parts numbers Issue 57 (First Generation) Responding to a query of whether a dual-diaphragm vacuum pump on First Generation trucks can be rebuilt, a member provides parts numbers for canisters, gaskets, seals, bearings, bushings, and rods. 28 Valve adjustment, specifications Issue 58 (5.9 HPCR) Joe Donnelly gives specifications for adjustment of intake and exhaust valve lash in the HPCR engine, and references coverage of the subject in earlier issues of TDR. 40 Valve seat, “dropped”. See Exhaust gas temperatures, excessive Variable-geometry turbocharger (VGT) Issue 57 (6.7 HPCR) Joe Donnelly notes that the new 6.7-liter engine is equipped with a variable geometry turbocharger, which increases high-altitude capability and, with the exhaust brake, reduces vehicle-brake wear. 54 Vibration problems in Jeep Liberty, corrected by an aftermarket torque converter. See Jeep Liberty, VM diesel option, performance problems with Visualization techniques to improve driving responses Issue 57 (Motor-Minded) Mark Barnes proposes borrowing conditioning techniques from sports, in which challenges are rehearsed and visualized in advance in a state of highly suggestible deep relaxation, to prepare better response patterns on the road. 142–143 Warranty, constraints, in use of fuel additives Issue 59 (Letter Exchange) TDR advises readers to follow the instructions of the warranty guarantor when there is a difference between those of Cummins and Dodge concerning use of fuel additives in the 6.7-liter engine. 8 Warranty, extended, advice concerning Issue 57 (Ranch Dressing) John Holmes advises buying extended warranties only from the original maker, and gives an example of a fraudulent policy by a third-party provider. 103 Issue 58 (From The Shop Floor) Andy Redmond advises caution and circumspection before purchase of third-party extended warranties. 146 Wastegate, adjustable, aftermarket Issue 57 (TDRelease) BD’s electronic “Boost Builder” adjustable wastegate increases fueling to raise boost levels for added performance. 161 Wastegate, single vs. dual volute Issue 59 (Have Ram, Will Travel) Joe Donnelly explains the difference in design and function between single and dual volute wastegates, the former with the stock Holset HX35 turbocharger in Second Generation trucks, the latter with enhanced power. 95–96 Wastegating of compound turbochargers Issue 59 (Have Ram, Will Travel) Joe Donnelly describes the two arrangements for wastegating compound turbochargers. 96 Water leak in cab at headliner and grab handles, diagnosed Issue 57 (5.9 HPCR) Readers note that a poor-quality gasket under the cab clearance lights explains water leaks in the cab, addressed by a service bulletin. 42 Wheel, aftermarket upgrade Issue 57 (Member2Member) To accommodate a larger tire to the space in the wheelwell, Doug Leno upgrades his wheels to the Centerline Vector 2. 12 Wheel, measuring and calculating offset and backspace Issue 57 (Member2Member) Doug Leno explains the difference between offset and backspace measurement, and implications for fit and performance, when increasing wheel size. 12–13 Wheel and tire, upgrades Issue 58 (Member2Member) Doug Leno likes the looks and performance of Centerline rotaryforged aluminum wheel and Toyo Open Country MT tire. 12 Wheel bearings, RV, maintenance. See Trailer wheel bearings, protection against failure Wheel flares, aftermarket Issue 58 (Member2Member) Doug Leno appreciates the aesthetic enhancement of his ‘04 Quad Cab afforded by his unpainted Bushwacker wheel flares. 12 Wheels, “super-singles” displacing duallies. See Super-single wheels and tires TDR 61 www.turbodieselregister.com 67 TDResource . . . . Continued Wheels, aluminum, difficult to remove from hubs Issue 57 (5.9 HPCR) It is essential that a wheel firmly grip the hub, but if aluminum wheels seize up on the hub, clear-coat paint would do the job and be less slippery, opines Joe Donnelly. 40 White Lightning, a Turbo Diesel modified for ultimate speed. See Demonstration truck, modified for ultimate power and speed Winch, capacity of the Warn HS9500i Issue 59 (Member2Member) Answering a question about capacity of the Warn HS9500i winch, Joe Donnelly refers to his comprehensive roundup on winches and related accessories in TDR Issue 51, pp. 28-44. 16 Window, power, repair Issue 57 (First Generation) Members consult among themselves on way to repair a broken power window assembly in the First Generation truck. 24 Window air-deflector, aftermarket Issue 58 (Back In The Saddle) Scott Dalgleish describes the function and merits of a window air deflector, available in several versions, made by WeatherTech. 114 Wire Electrical Discharge Machining (wire-EDM) process. See Injector nozzle, machine modification of Wireless control module (WCM), failure. See Engine startup problems, troubleshooting Wiring through the firewall. See Accessory installation, in-cab, savvy advice for simplifying the job 68 www.turbodieselregister.com TDR 61
