2001 Dodge Ram 1500

Pickup Truck

3.9L 4BT Cummins Turbo Diesel

Manual

1B7HC16Z91S197522

Clear

Diesel

The original goal of this project was to build a 1/2 Ton truck that could get fuel economy superior to any other 1/2 Ton on the market, using a diesel engine. The big three truck manufacturers promised us a diesel half ton several times, but have failed to deliver. So I took the initiative to build the truck they haven’t. In addition to being a diesel, I wanted it to look and work as close to OEM as possible. Therefore I used a donor Dodge Ram 3500 to switch the Ram 1500 over. Many of the parts on the finished truck are easily obtainable factory parts, which can be sourced from auto parts stores. Attention to detail was key, from the hydro-boost, to the turbo charger, and even to the diesel start instructions on the back of the sun visor. The transmission and clutch are from the 01' Dodge Ram 3500 and the engine was extracted from a step-van. The truck runs with the 5.9L Cummins 6BT 24V ECU hooked up to provide the Dodge PCM with sensor data. I also connected up as many sensors as possible to satisfy the gauges. The average diesel fuel economy is currently 24-26, max. 28 miles/gallon. The user can naturally have the tuning of the injector pump adjusted to provide the required turbo boost, torque, and fuel economy. Please check out the additional pictures and videos in the links provided below! The build was documented here: http://www.4btswaps.com/forum/showthread.php?3928 This forum is the ultimate resource for the 4BT builder & owner. Video: http://www.youtube.com/watch?v=SqqtYWHlow8 http://www.youtube.com/watch?v=6YsM2lNPR-Q http://www.youtube.com/watch?v=sOspMbolBSE Additional Pictures: https://plus.google.com/photos/102378049495141044248/albums/5185239836359604545 I have detailed pictures of the build as well as information which could answer many of your questions. Thanks! Original Equipment: - 5.9L V8 Gas Engine - 46RE Transmission (4-Speed Auto) - Air Conditioning – not hooked up, parts included - Cruise Control – not hooked up, parts included Pre-Diesel Conversion Upgrades: (front the back of the truck forward) - “Ram” Taillight Covers - Fiberglass Roll Pan (needs repair, see pictures), APC Brand (no longer in buiness) - Custom made hidden hitch (behind license plate) by professional & reputable company rated at 8000lbs ($550.82) - Bell-Tech Drop Hangers for rear 3-4” lowering (just below level with air bags at 0psi) BellTech P/N 6580 http://www.belltech-store.com/shackle-hanger-kit-8664.html http://www.summitracing.com/parts/BEL-6580/ The factory Shackles are in place, not the Bell-Tech ones. - Leaf Spring Bushings & Shackle Bushings were replaced with Polyurethane bushings from Energy Suspension. - AirLift Kit (for 1+ Ton Trucks) P/N 57215 & Compressor P/N 16060 ($316.16) http://www.summitracing.com/parts/AIR-57215/ http://shop.airliftcompany.com/product/0/57215/_/LOADLIFTER_5000%3B_LEAF_S PRING_LEVELING_KIT http://www.summitracing.com/parts/AIR-16060/ http://shop.airliftcompany.com/product/0/16060/_/ELECTRIC_12V_AIR_COMPRESSOR - Genuine Dodge Clearance Lights & Genuine Dodge “4x4 Off-Road” Sticker modified to “4x2 Off-Road” ($133.84) - Flex-A-Light Monster Electric Fan Setup w/Custom Brackets – P/N 290 ($460.16) http://www.flex-a-lite.com/auto/html/monster- electric.html http://www.summitracing.com/parts/FLX-290/ - Custom Washer Fluid Tank, & Coolant Overflow Tank Diesel Conversion Upgrades: - Cummins 3.9L 4BT Turbo Diesel Engine Serial #44783064 ($1525) - Cleaned, & Painted with POR15 ($84.05 for paint) - Valve Covers & Intake Manifold Plate given a “Brushed Aluminum” finish. - Custom Exhaust Manifold (Chopped &Welded 6BT Manifold) - Custom Alternator Bracket - 3” Custom Intake Pipe, Mandrel Bent,High Polish Stainless Steel - OEM Factory Dodge Ram Intercooler - Piston type lift pump (far superior to diaphragm pump) - Reinforced frame & Custom Motor Mounts - NV5600 Transmission, Painted with POR15 - 13” HD Clutch, Resurfaced Flex Plate (hold more torque than the engine could ever reasonably make) ($595.37) - Holset HY35 Turbo, can boost over 30psi. ($382.70) - Dual Type 27 NAPA Legend Batteries - 4-Wheel Antilock brakes from Dodge Ram 3500 (adds independent front wheel ABS to single rear axle ABS aka RWAL) Kelsey-Hayes EBC 2 ? Kelsey-Hayes EBC 325 - Added New Front Wheel Bearings w/ABS Rings & Wheel Speed Sensors ($367.01) - Electric Vacuum Pump to run the HVAC controls & possible cruise control (cruise control is not hooked up) - Fully functional dual-element grid heater which runs off of the Diesel Dodge PCM/Cummins ECU. LEDs in the cabin to tell you they're on or not. - 4” Stainless Steel Exhaust from Turbo back (no reductions anywhere) ($410.70) - Amsoil By-Pass Filter & Full Flow Filter Kit ($245.80 without filters or adapter) http://ww2.amsoil.com/shop/by-product/filters-and-by-pass-systems/by-pass/filters-and-mounts/general-use-dual-remote-oil-bypass- unit/ - Bilstein Heavy-Duty Shocks all around ($247.80) - Autometer Gauge Pillar (2-Gauges & Tweeter) - Autometer Cobalt Pyrometer 0-2000 deg F - Autometer Cobalt Boost 0-60 psi - Giant K&N Cone Filter http://www.summitracing.com/parts/KNN-RU-5045 - Extensive Dynamat install on engine side of firewall, doors, & floor. I have more left over too. ($361.84) - Upgraded front springs to springs for a Dodge Ram 2500 with 8500GVWR. The factory springs were bottoming out with the increased weight. The weight also forced me to upgrade my tires from LT tires to Load Range E. Load range C or D tires would be adequate also (Anything 50psi or greater). Power Modifications: - 366 RPM Spring – Increases maximum RPM from 2800 to 3200 RPM - “Denny-T” Fuel Pin, except, not Denny-T brand. This pin was purchased from Tennessee Diesel Conversions which offers as superior quality & performing product. The pin increases the maximum fuel delivery. Tires & Wheels: - 4x Goodyear Tracker 2, 235/85R16, Load Range E (Rear tires are almost new, front are older with decent tread) - Rims are stock Dodge steel painted matte black - Also included are the original Dodge aluminum 16” silver rims Documentation, Paperwork, & Information: - Genuine Manufacturer 2001 Dodge Ram Service Manuals Volume 1&2, Chassis Diagnostic Procedures, & Diesel Powertrain Diagnostic Procedures ($123.95) - Personalized Cummins Prepared Parts Catalog specific to my engine. The build was documented here: http://www.4btswaps.com/forum/showthread.php?3928 This forum is the ultimate resource for the 4BT builder & owner. Video: http://www.youtube.com/watch?v=SqqtYWHlow8 http://www.youtube.com/watch?v=6YsM2lNPR-Q http://www.youtube.com/watch?v=sOspMbolBSE Additional Pictures: https://plus.google.com/photos/102378049495141044248/albums/5185239836359604545 I have tons of more information in print, on my computers, and in my head. I'm more than willing to provide the buyer with future information, ideas, & suggestions. History: - I acquired the truck on 12/21/02 as the second owner with 22835 miles. - On 4/4/2008 I had 75086 miles on the entire truck with the gas engine. - At ~75239mi I swapped the gauge cluster with a diesel on that had 178897 miles. (therefore there are only 18,588 miles on the conversion, and 93,827 miles on the body & frame!) Some parts have even less miles on them. - I drove the truck daily for work from December 2009 to January 2011 when I purchased another car. I only had one issue in -20 degree weather starting after being parked for 12+ hrs. I was unable to plug in the block heater. - Truck was featured on the back of the TDR 2012 catalog. Why Am I Selling It? I'm driving further to work now in city traffic and it's not as practical as my 2011 Honda Civic. The wife can't drive manual either, so it's just left sitting now that she has her new Rav4. I'm moving to a new house next month and don't have the space for an extra vehicle anymore. I love this truck, and I've had it since I was 15, but now at 26, I need the money to help start my family. I hate to see it go, but the wife says it has to! I have spent over $15,000 on this truck, not including the value of the truck, and after selling off unused parts. I am taking a big loss here as is to be expected with such a project. It could not be done for less than $10,000 today, especially to this precision, attention to detail, and quality of work. Remember $15,000 excludes any labor. Known Issues: - Parts of the truck have nearly 200,000 miles on them. These parts include the alternator, starter, transmission, and others. The body of the truck is nearing 100,000 miles, and many of the other parts in the truck have been replaced and have less mileage. Everything has normal wear for it's age, but since I don't beat on the truck it's in overall good shape. - The body is not perfect. There are small dents, scratches and rusting areas. This was a truck that was used, not a show truck. I'm not a body guy either. It could definitely use some light body work and then could look great! The truck has NEVER been in an accident to my knowledge. (with the exception of the driveway incident with my mom's VW damaging the rear roll pan/bumper) - This is a Cummins engine, it leaks from various places, nothing significant. - The power steering system is 100% custom, and could be upgraded by getting rid of the reservoir on the pump to use only a remote reservoir. It leaks when sitting. - Weight distribution is not great, therefore without any load in the bed, braking is greatly reduced and the rear will lock up. Either don't drive like a maniac or sand bags solve the problem. The truck is good for a 2WD in the winter (I add 5 sand bags). - Under-Heating Issue which may be and should be a simple fix. I have simply been unable to solve it or even pin point the cause. I can get it to temperature, but without cardboard, it will never get there. This is an issue I'm willing to help the next owner out with. It might just be an issue of finding the right part number for an O-Ring or Thermostat. - The fuel gauge is not accurate and the sender could use to be replaced. I just refill the truck every 400 miles and I've never run out that way. - The tachometer is not hooked up because I don't have a pickup sensor that matches the signal the Cummins 24 Valve ECU is looking for. I have a microprocessor generated signal that generally sits the gauge around 1200 RPM so that the alternator functions (it will not without a valid tachometer signal) It is possible to get the tachometer functioning, but would take some effort & time. - Air Bag light is on because I had to change the driver's airbag out due to a bad clock spring. I think the dealer could just reset this. Additional Information: - The truck was just serviced at Huckstorf Diesel in Franklin, WI. It had the injection pump completely gone through and repaired on October 6th, 2012. It was reset to manufacturer specifications and has a 1 year warranty on the pump through Huckstorf. Therefore it does not currently reach the same performance level it did prior. If the buyer had Huckstorf tune the truck for you on their dyno this would enable you to retain the warranty. I did not want to adjust the fuel settings and loose the warranty. I paid $1339.95 in labor & parts for the rebuilt pump to be installed. Receipt: - On October 7th, 2012 the truck received brand new quality NAPA rotors & brake pads in the front. I paid $169.60. Receipt: - On October 12th, 2012 the truck received a brand new K&N Air Filter. - The truck is 100% street legal in Illinois. It is exempt from emissions testing because it is a diesel. The state of Illinois recognizes this truck as a diesel formally on paper. Not many diesel conversions of Post-1997 vehicles can say this! It comes with a perfectly clean Illinois title. I am the second owner (owned it for 10+ years). The vehicle may have more miles by the end of the auction, but not more than a few hundred (at most). Extra Parts Included: (incomplete list) - 2x 5-Gallon Tub Mobil Delvac 15W40 ($100) - Amsoil Full Flow Filter - Amsoil By-Pass Filter - 3 Quarts Amsoil Gear Oil & Permatex Gear Oil RTV (due for differential oil change) - 2x A/C Compressors - DynaMat - Several Sheets - DynaHood Liner - 5" Exhaust Tip - 01' Cummins 24V Fuel Heater/Filter Assembly - 01' Cummins 24V Electric Fuel Pump - ANY MANY OTHER VALUABLE PARTS! Disclaimer: This is a project truck. I highly advise the buyer be an experienced person mechanically and electrically when it comes to automobiles. Otherwise have a relationship with someone who knows these great engines. I don't recommend relying on it for a daily driver right off the bat as it needs a few issues sorted out as explained above. This would be a great “father-son” project or truck for someone who loves all things Diesel. No warranty is implied or suggested. The truck is sold AS-IS.