Hot Rod RV Ram: A 1997 Dodge Ram Cummins For The Modern Age

Throughout the pages of Diesel World, you’ll see anything and everything, from innovative swaps, to 1,000-horsepower street trucks, to all-out competition vehicles. While the glamorous stuff can be fun, almost everyone still needs a reliable daily driver, a truck that can tow thousands of miles, doesn’t smoke and attract the smog police, and is just a good all-around vehicle. We know that people need this type of truck, because those are our most common letters; people wanting “just a little bit more oomph” out of their diesel, without sacrificing reliability or driving manners.

Enter Project Hot Rod RV Ram

While new trucks are pretty awesome, with their seat heaters, built-in exhaust brakes, and 350-400 horsepower, not everyone can afford their $50,000-plus price tag. Our goal would be to take an older truck and modernize it as far as creature comforts, horsepower and torque levels, and ride quality. Oh yeah, and it still would have to be able to do anything a new truck could do, like blast up grades with a camper and trailer. The truck we chose for this project was a 1997 Dodge Ram 2500 with a 5.9L 12-valve Cummins diesel.

Dodge 12-Valve Basics

The 1994-1998 Dodge Rams have perhaps the most potential of any older truck, and built correctly, can be very efficient as far as mileage goes, and also very low on smoke. They’re also the trucks you might see most commonly “rolling coal,” so whether our truck will have lots of smoke or almost zero smoke will inevitably come down to tuning.

The 5.9L Cummins engines in these Dodges (affectionately known as “12-valves”) have one of the best reputations for reliability out there. When maintained, we know of many of these engines that have lasted 300,000 to 500,000 miles without a need for a rebuild, and some that have went even further. One fellow we talked to had 640,000 miles on his, and had only done gaskets, rings and bearings when he rebuilt it. Last time we talked to him, he had more than 800,000 on it.

So the Cummins engines are tough, but what about power? Well, the good ole 12-valve does pretty well there too. In stock form, they were rated at 160-215 hp in Dodge trucks (depending on the year and model), but there was a catch. In Marine form, you could get a Cummins with up to 370 hp, which means that the engines were built for that type of power in mind. What’s more, doubling the factory output of the truck engine would be just a few simple changes away once we started modifying.

Inside Our Truck: A 1997 Dodge Ram 2500 Diesel

When looking for one of these older Dodges, the prices can fluctuate wildly, from about $5,000 to $15,000, depending on the condition of the vehicle. Although ours was a two-wheel drive (which meant it would be worth less), it only had 153,000 original miles, which is hard to find these days. The transmission had also supposedly been rebuilt, and some firm shifting led us to believe that the owner was probably telling the truth. The engine had also been modified with a different fuel plate, allowing for some more top-end fueling and power, and this too seemed to be true, as bone-stock 12-valves are painfully slow. Still, we won’t know anything until we get to a dyno and put some power to the ground.

So Where To Start?

Well, our first step will be to tackle reliability, since power won’t do you much good if your truck is broken in the driveway. These generation engines have a dowel-pin fix we’ll have to perform, and we also have a leak from our fuel return line (another common problem). We’ll also show you how to re-torque the factory head bolts, which is important as the years and mileage increase. After the basics, we’ll move on to increasing power, by adding timing, sliding the fuel plate, and a host of other simple modifications. Our goal is to keep up with the “Joneses,” with the Joneses being new trucks in this case.

Since all of them put down 350 hp to the wheels, that too will be our goal. We also plan to increase the rev limit of our truck to try to save the transmission, as often burning up a Dodge transmission is a result of too much low-end torque rather than too much horsepower. After power and reliability, we’ll move on to the interior, lighting, gauges and anything else we need to modernize our ride. Stay tuned in the next few months, where we’ll start fixing problems that are common to the 1994-1998 Dodges, which are of course issues that our truck already has. DW

FREQUENTLY ASKED QUESTIONS

What is the significance of the high-flow head and fire-rings in the engine modifications?

The high-flow head and fire-rings play crucial roles in enhancing the engine’s performance and durability. The high-flow head, featuring precision port work, significantly increases airflow on the intake side—from the stock 155 cfm to an impressive 220 cfm. This enhanced airflow enables the engine to burn more air-fuel mixture efficiently, ultimately boosting power output and improving overall engine performance.

Meanwhile, the inclusion of fire-rings in the modified engine’s design serves to bolster the engine’s strength under high pressure and temperature conditions. By cutting both the block and head to accept fire-rings, this modification ensures a superior seal between them, effectively preventing gas leaks under the extreme conditions associated with increased performance. Such features become particularly significant when paired with the engine’s other upgraded components, like ARP main and head studs, which further reinforce its capability to handle enhanced performance levels reliably.

What modifications have been made to the 48RE transmission in the truck?

The 48RE transmission in the truck has undergone several key modifications to enhance its performance. First, it’s equipped with a solid, 37-spline input shaft, and enhanced by a Sonnax billet intermediate and a TCS fat billet output shaft—all designed to increase strength and reliability. To improve the drivability and help spool up the large single turbo, a four-disc torque converter with a 2,400-rpm stall speed is installed.

Additionally, precise control over gear shifts and converter lockup is achieved with a high-pressure, full manual valve body. These upgrades collectively ensure the transmission handles increased power demands while providing smooth operation.

How has the turbo system been enhanced in Paul’s Dodge Ram?

Paul’s Dodge Ram has undergone an impressive turbo system enhancement that significantly boosts its performance. At the heart of this upgrade is a turbocharger rooted in the robust S400 platform, courtesy of Stainless Diesel. This turbo includes a sophisticated billet, 5-blade compressor wheel with a 75mm inducer, which ensures efficient air intake for optimal engine power.

To optimize exhaust flow and turbo responsiveness, there’s an 87mm turbine wheel paired with a 1.0 A/R exhaust housing, designed for quicker spooling. This setup manages to push a substantial 55 psi of boost pressure through an upgraded intercooler system, ensuring cooler and more oxygen-rich air reaches the engine.

For durability and aesthetic appeal, the compressor housing shines with a polished finish, while the exhaust housing benefits from a hot ceramic coating to prevent discoloration and rust. A T4 Steed Speed exhaust manifold securely mounts the turbocharger, effectively channeling exhaust gases through a custom exhaust system. This system begins with a 4-inch downpipe and expands into a robust 5-inch conventional exit, allowing for improved exhaust flow and reduced back pressure.

What cosmetic and stance upgrades have been made to the truck?

Cosmetic and Stance Upgrades on the ’07 Dodge Ram 2500

The ’07 Dodge Ram 2500 has undergone several stylish enhancements to boost its appearance and stance. Here’s a breakdown of what’s been done:

• Lighting Upgrades: The truck now features sleek clear headlights, providing a modern touch that sharpens its front-end look. To complement these, smoked cab lights, along with updated taillights and a third brake light, add a sophisticated, cohesive lighting theme to the vehicle.
• Mirror Modifications: New Boost Auto mirrors have been installed, enhancing both the visual appeal and functionality of the truck—the perfect blend of form and function.
• Body Adjustments: For a more aggressive stance, the front has been lowered by 2.5 inches, giving it a bolder and more streamlined presence on the road.
• Rear Alterations: In an effort to balance its stance and improve maneuverability, the rear modification includes the removal of three leaf springs. This not only contributes to the truck’s sleek posture but also impacts its ride dynamics favorably.

These changes collectively give the truck a refreshed and contemporary appearance while preserving its rugged, durable essence.

How does the truck manage to stay rust-free despite being in a harsh climate?

How the ’07 Dodge Ram 2500 Defies Rust in Harsh Climates

Paul Szczypta’s 2007 Dodge Ram 2500 stands as a testament to enduring quality, maintaining a rust-free exterior despite spending years in the salt-laden environment of the Midwest. But how does it manage this seemingly impossible feat?

The answer lies in a combination of strategic care and inherent design properties.

• Protective Treatments: Regular applications of rust inhibitors play a pivotal role. Many owners swear by products like Fluid Film or Rust-Oleum that create a protective barrier against moisture and salt.
• Thorough Cleaning: Consistent washing, especially in winter months, helps remove corrosive road salt. By focusing on reaching those hidden nooks and crannies in the undercarriage, Paul effectively prevents the buildup that leads to corrosion.
• Inspection and Repair: Regular inspections for chips and scratches on the paint allow for prompt touch-ups. This preemptive action helps in thwarting corrosion before it gains a foothold.
• Innovative Design: Dodge Rams are known for their solid construction, using galvanized steel and strategic rust-proofing methods during manufacturing, which provides a robust first line of defense against the elements.

Through a disciplined maintenance regimen and the truck’s resilient build, this ’07 Dodge Ram 2500 continues to defy the odds, showcasing not only its durability but also the practicality of vigilant vehicle care.

How rare is it to find a rust-free, low-mileage third-gen Dodge Ram truck?

Finding a rust-free, low-mileage third-gen Dodge Ram truck has become increasingly rare. These trucks, especially those produced between 2003 and 2007 with a Cummins engine, have gained collector appeal due to their durability and performance. However, the combination of time and environmental exposure means many of these trucks have accumulated significant mileage or developed rust.

As time passes, the pool of well-preserved examples shrinks, making them much more sought after by enthusiasts and collectors. Spotting one in excellent condition is often likened to discovering a hidden gem, as they are few and far between in today’s market.

So, if you come across a third-gen Dodge Ram that hasn’t succumbed to rust and still boasts low mileage, consider it a rare find.

How well preserved is the interior of Paul’s third-gen Dodge Ram?

Paul’s third-generation Dodge Ram boasts an impressively preserved interior. Despite being nearly 17 years old, the truck has maintained its charm remarkably well. The leather seats, showing no signs of tears or heavy wear, suggest that the vehicle’s 113,000-mile journey hasn’t taken much toll on the inside. During a recent photo session, the original interior components, including SLT trim seats, the center console, and door panels, appeared to be in pristine condition. However, Paul has since upgraded them to SRT10 versions for an enhanced look and feel.

What engine specifications and upgrades does Paul Szczypta’s ’07 Dodge Ram 2500 have?

Paul Szczypta’s ’07 Dodge Ram 2500 boasts an impressive array of engine upgrades and specifications that enhance its performance significantly. At its core lies a 5.9L common-rail Cummins engine, which has been meticulously upgraded for maximum power and efficiency.

Key Engine Upgrades:

• Internals: The engine block houses durable components such as ARP main studs for securing the main caps, and Wagler Competition Products’ Streetfighter rods, ensuring robustness under stress. The addition of valve-relieved Mahle pistons within the standard cylinder bore maintains the right balance between performance and reliability.
• Cylinder Head: Atop the block is a Stage 1 cylinder head from D&J Precision Machine, carefully modified to include fire-ring grooves. This high-flow head is equipped with advanced 5-axis porting, which significantly enhances air movement. The intake side now achieves 220 cubic feet per minute (cfm) of flow, compared to the stock 155 cfm. It’s anchored in place using ARP Custom Age 625+ head studs for enhanced seal integrity.
• Valvetrain Enhancements: Complementing the head work are upgraded 105-pound valve springs. These springs help maintain valve control at high engine speeds, making the engine more responsive and resilient.

Overall, Paul’s Dodge Ram 2500 is a testament to thorough engineering and performance tuning, making it a powerhouse vehicle built to tackle demanding conditions with ease.

What role does the AirDog II-5G fuel supply system play in the truck’s performance?

The Essential Role of the AirDog II-5G Fuel Supply System in the Truck’s Performance

The AirDog II-5G fuel supply system plays a crucial role in maximizing the truck’s performance, especially when aiming for high horsepower outputs. Strategically positioned along the driver side frame rail, this system is designed for maximum efficiency and discretion, ensuring it operates silently while being invisible to the observer.

Key Functions:

• Fuel Delivery Precision: It ensures a steady and robust flow of fuel from the tank, vital for the engine’s optimal functioning. This system effectively pulls fuel from the factory tank using a 4G lift pump, which then channels the fuel through a half-inch hose to further engine components.
• High Flow Rate: Capable of flowing at an impressive rate of 165 gallons per hour, the system maintains the engine’s demand for fuel, which is essential when you’re looking to achieve a high power output, such as 800 rear wheel horsepower (rwhp).
• System Integration: While seamlessly integrated into the vehicle’s architecture, the system works tirelessly to ensure that modifications to the injection system are fully supported, making it indispensable to enhancing the truck’s overall performance capabilities.

By maintaining a consistent and high-volume fuel supply, the AirDog II-5G system enables the truck to operate smoothly at elevated performance levels, showcasing its indispensable role in powering high-output engines.

What makes third-generation Cummins diesel-powered Dodge Ram trucks from 2003-2007 a hot commodity?

Why Are 2003-2007 Third-Generation Cummins-Powered Dodge Ram Trucks So Sought After?

If you’re searching for a truck that offers both nostalgia and performance, the 2003-2007 Dodge Ram models equipped with the Cummins diesel engine are in high demand. Here’s why these vehicles have become a hot commodity:

• Legendary Engine: These trucks are powered by the revered 5.9L Cummins inline-six engine. Known for its exceptional durability and reliability, this engine is a favorite among diesel enthusiasts.
• Emission Simplification: Unlike their successors, these models lack the complex emission control systems such as EGR (Exhaust Gas Recirculation), DPF (Diesel Particulate Filter), and SCR (Selective Catalytic Reduction). This simplicity often translates to fewer mechanical issues and easier maintenance.
• Collector’s Item Status: As the years pass, finding models in pristine condition—meaning rust-free and with low mileage—has become increasingly rare. This scarcity adds to their appeal as collector’s items.
• Robust Performance: The 2500 and 3500 models are renowned for their towing and hauling capabilities, making them perfect for both work and play.

In summary, these third-generation Dodge Rams offer a blend of simplicity, power, and reliability that continues to capture the attention of truck enthusiasts and collectors alike.

How does the truck maintain drivability and reliability with high performance upgrades?

“Well, our first step will be to tackle reliability, since power won’t do you much good if your truck is broken in the driveway. These generation engines have a dowel-pin fix we’ll have to perform, and we also have a leak from our fuel return line (another common problem). We’ll also show you how to re-torque the factory head bolts, which is important as the years and mileage increase.

After the basics, we’ll move on to increasing power, by adding timing, sliding the fuel plate, and a host of other simple modifications. Our goal is to keep up with the “Joneses,” with the Joneses being new trucks in this case.”

To ensure the truck maintains drivability and reliability alongside these high-performance upgrades, precise adjustments to the electronic control module (ECM) are essential. These ECM tweaks are crucial for not only enhancing performance but also for maintaining a clean-burning and efficient engine.

• ECM Adjustments: By fine-tuning the ECM, we can balance the power increase with fuel efficiency and emissions control, ensuring the truck remains practical for everyday use.
• Reliability Enhancements: Addressing common mechanical issues like the dowel-pin and fuel return line leaks form the foundation of our approach, while re-torquing head bolts helps sustain engine integrity as the truck ages.

Combining these strategies allows the truck to deliver the desired power levels without sacrificing reliability or drivability, effectively bridging the gap between older engines and the performance of newer models.

Who is responsible for ensuring the truck’s performance and reliability?

An expert from Hardway Performance, specifically Ryan Milliken, is noted for making the necessary adjustments to maintain the truck’s optimal performance.

What role does the electronic control module (ECM) play in high-performance vehicles?

The ECM is crucial for balancing high performance with everyday usability, as it allows for fine-tuning that keeps the engine clean-burning and reliable.

How are drivability and reliability maintained with high-performance upgrades?

Drivability and reliability are achieved through precise adjustments to the vehicle’s electronic control module, ensuring the truck remains both powerful and dependable.

What tire and wheel combination is used on the truck, and how does it affect performance?

If you plan on keeping your truck for the long haul (ha!), a good set of tires is always a welcome sight. These Michelins mounted on the factory wheels gave a great ride, and were something that we will be hard pressed to change out for a different set of tires.

For those looking to upgrade, consider a setup like the Nitto NT420V all-seasons, which excel in high torque diesel applications. They boast a robust performance that minimizes tire slip when locked in 4-High. Each tire measures 32.5 inches in diameter and 12.4 inches in width, providing a substantial footprint for enhanced stability.

Pair these with a set of polished, 24×12-inch wheels to not only elevate the truck’s look but also bring a touch of modern functionality. This combination effectively bridges classic style with contemporary performance, ensuring your ride stands out while handling the road with ease.

What is the aesthetic or functional impact of the wheel and tire combination?

The combination modernizes the vehicle, bringing an older model into a more contemporary era both in terms of looks and function.

How does the tire and wheel combination affect performance?

This combination effectively reduces tire slip in high torque diesel applications when in 4-High, enhancing overall performance.

What type and model of wheels are used?

The wheels are 24×12-inch Independence model from American Force.

What are the tire dimensions?

The tires have dimensions of 305/35R24, with an overall diameter of 32.5 inches and a width of approximately 12.4 inches.

What type and model of tires are used?

The tires used are all-season Nitto NT420V.

What is the horsepower potential of the modified Cummins engine in the truck?

In Marine form, you could get a Cummins with up to 370 hp, which means that the engines were built for that type of power in mind. What’s more, doubling the factory output of the truck engine would be just a few simple changes away once we started modifying.

To achieve this impressive boost, the engine benefits from a high-performance common-rail injection system. A 14mm stroker CP3 high-pressure fuel pump, capable of supporting over 1,400 horsepower, is a key component. This pump sits in the factory location, channeling over 26,000 psi to a larger fuel rail sourced from a 6.7L Cummins.

The transformation doesn’t stop there. A set of 200-percent over injectors ensures that the engine receives the precise amount of fuel needed for optimal performance. Tweaks to the ECM (Engine Control Module) ensure the modifications yield a truck that’s not only powerful but also drivable, clean-burning, and reliable.

By integrating these components, the modified Cummins engine taps into its full potential, showcasing a remarkable increase in horsepower that’s both achievable and practical for those seeking to maximize their truck’s performance.

What is the role of the ECM in these modifications?

The ECM tweaks are crucial for integrating the modifications, ensuring the vehicle operates smoothly and efficiently without sacrificing drivability or reliability.

Who is involved in optimizing these modifications?

Ryan Milliken from Hardway Performance is responsible for fine-tuning the engine control module to ensure these modifications work seamlessly.

How do these modifications affect the engine’s performance and drivability?

The modifications ensure the vehicle remains easy to drive, environmentally friendly, and reliably powerful, maintaining a balance between performance and practicality.

What modifications are made to achieve this horsepower?

Key modifications include upgrading to a high-pressure fuel pump, enhancing the fuel rail from a larger Cumminsengine, and installing injectors with significantly increased capacity.

What is the maximum horsepower potential?

The setup is capable of supporting over 1,400 horsepower, showcasing its impressive power capabilities.