TimWaagBlog: Final Build: 2006 Dodge Cummins 2500 G56 6 Speed Manual Transmission Standard Cab Long Bed

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LUBRICANT FOR G56 TRANSMISSION:
There has been much controversy regarding lubricant selection, with many owners and industry experts arguing that using ATF+4 to lubricate the transmission, as Chrysler recommends, can cause it to fail prematurely. Mercedes-Benz recommends a thicker 75W or 90W gear oil in their trucks that are equipped with the G56. It is debatable whether anything is gained by switching to a 75W/90W gear oil, but many owners choose to do so. A tooth was removed from the input shaft gear for the 2007.5 model year, resulting in a ratio change for the 6.7L Cummins version. When equipped in 6.7L applications, torque was derated to 610 lb-ft for 2007.5 to 2012 model years, and has been derated to 660 lb-ft for 2013 to current model years. Meanwhile, the Cummins Turbodiesel is available with up to 900 lb-ft equipped with an automatic transmission.

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Safe.

https://www.consolevault.com/dodge-ram-under-seat-console-2006-2019.html
Console Vault $269.

https://guardiansafeandvault.com/collections/dodge/products/locker-down-safes-console-safe-2006-to-2018-dodge-ram-1500-2500-3500-and-2019-except-1500-under-front-seat-model-ld2058
Guardian Safe and Vault $289.

https://www.amazon.com/Console-Vault-Under-06-13-Keyless/dp/B003LCTCAS
Console Vault Under Seat Console Gun Safe 06-13 Dodge Ram w/ Keyless Combo Lock $327

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CUMMINS 5.9L HO MANUAL TRANSMISSION OVER REV 10/20/2019

Kelly, thanks for getting back to me so fast.

Its probably NOT a rough idle condition. I get PARANOID after this over rev, and I think I “HEAR THINGS” that don’t actually exist.

Remember, I’m still towing 12,000 pound homeless shower trailers up the grade with no discernible lack of power, so rationally

I did not damage to my engine. Your crew confirms that with the "virtually impossible to cause internal engine damage on your 5.9”

statement. That is the expert information that I was hoping to get from your shop.

I change my fuel filter with high end filters every 10k. (there’s the PARANOIA AGAIN!).

Correct. No codes. Turbo is good too, as those 12,000 trailers really need to be rammed up the 9% Cuesta Grade.

I run them in 5th gear at about 50mph all the way up the grade.

Truck has 111k on it. Valves adjusted at 100,626 miles.

• VALVE ADJUSTMENT: SchB 135k, SchA \ 150k; Cole Dodge says 80k-100k. 100,626 --> [next adjustment 150k]

Again, there is probably NO IDLE DIFFERENCE WHATSOEVER. JUST ME HEARING SOMETHING THAT IS NOT THERE.

Frankly, Cummins 5.9 is not as smooth idling as my Ford 7.3 power stroke, for instance.

Kelly, you gave me EXACTLY what I needed to know, and I thank you for always being there for my silly questions.

Take care, my friend.

—Tim

On Oct 22, 2019, at 9:52 AM, Kelly Wall <kwall@coleautos.com> wrote:

Hello Tim, and yes it was nice to see you.

I talked to a couple of my Cummins guys about your rough idle. The good news is it’s virtually impossible to cause internal engine damage on your 5.9 by doing what you described on one occasion. ( the high rev ) With that said, what usually causes a rough idle would normally be fuel or turbo related. What’s strange is you have no apparent codes. Also, what you said about the valves maybe being out of adjustment is a possibility, but the only way to determine that is to remove the valve cover and re-adjust the valves.

So…what to do? If there is some fuel or turbo issue it’s tricky to diagnose without going deep with an extensive diagnosis ( fuel flow and fuel injector tests, bleed down tests etc. ) You may even want to consider perform a diesel induction service ( service the fuel injectors ). Personally If the idle is simply a subtle difference, I would live with it until it gets worse. A rough idle is not going to leave you stranded. Well, how’s that for a whole lot of “I don’t know?” Let me know if I can help. --Kelly

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HVAC GATE REPAIR 11/6/2019
- Remember to bring it in and see if all 5 gates need to be replacement or not...
- DIY you tube video: https://www.youtube.com/watch?v=7pFEQAy_m6Y
Detailed video on how to fix the mode doors on the Dodge Ram 1500, 2500, and 3500's. A common problem in these trucks is for the mode to be stuck on vent. This is due to a broken door inside the HVAC. There are many videos showing people cutting holes and bending metal brackets to access and replace the mode door(s), but TRUST ME, the way I am going to show you is FAR easier, and it is the RIGHT way to do it, with no cutting. It will probably take about 2 hours to do it, if you have a helper and the proper tools.

The replacement doors used in this video can be found here: https://www.amazon.com/gp/product/B00... https://www.amazon.com/gp/product/B00...

- "Remove Dash & Replace doors /actuaries) for HVAC gates
- Spoke with Jodi at Cole Dodge about HVAC gate repair. She quoted $1,680 for the repair with a complete 2 year warranty. I think I'll do it in April 2020, so as to maximize the warranty.
- Service Manager "Kelly Wall" insists that the plastic OEM Dodge gates have been upgraded and "should hold up".
- In any case, there are aftermarket metal gates that would not have any warranty whatsoever.
- Its a lot of money, so I'll probably at least call Santa Maria Dodge to see if they can do it with the 2 year warranty for less.

https://repairpal.com/estimator/dodge/ram+2500/hvac-blend-door-actuator-replacement-cost

The average cost for a Dodge Ram 2500 HVAC blend door actuator replacement is between $467 and $574. Labor costs are estimated between $404 and $511 while parts are priced at $63. Estimate does not include taxes and fees.

Note about price: The cost of this service or repair can vary by location, your vehicle's make and model, and even your engine type. Related repairs may also be needed. Talk with a RepairPal Certified shop to learn which repairs might be right for you.

What is a blend door actuator?

In a vehicle's heating and cooling system, the blend door actuators help control the air temperature from the vents, and direct air to selected vents.

How does the blend door actuator work?

To blow heat into the cabin, the blower motor sends air through the heater core and on through the dash vents. But when heat is not desired, the blend door actuators direct that airflow away from the heater core.

There are also actuators to direct air to the dash vents, floor vents and windshield vents depending which setting is selected.

What are the symptoms related to a bad blend door actuator?

The symptoms of a bad blend door actuator include a lack of heat or air conditioning, or failure of air to blow through some or all of the vents. The actuator motors may also make a noise if they've failed, but this isn't always the case.

Can I drive with a blend door actuator problem?

Driving with a bad blend door actuator may not be comfortable, but it won't hurt the vehicle.

How often do blend door actuators need to be replaced?

Blend door actuators fail frequently on some vehicles, but not in others. So, the rate of failure will depend on the vehicle make, model and year.

How are blend door actuator issues diagnosed?

The technician will test each vent position and temperature range. The amount of air and its temperature will be noted for each setting. If there's no change between settings, the blend doors are a strong possibility.

When these components are suspected, testing the circuit and observing them while they're working are the only ways to test them. The electrical wires or vacuum lines will be inspected to ensure the proper amount of power is being delivered. From there, the parts can be bench tested to pin down the problem.

How is a blend door actuator replaced?

Replacement procedures vary by vehicle. Some actuators will be easy to access, but others will require removing the airbags and dismantling the dashboard or parts of it. Most modern vehicles, especially those with dual climate control features and rear passenger air options, can have several blend doors and actuators.

RepairPal recommendations for blend door actuator issues

We don't recommend using DIY universal blend door correction kits, as these kits involve cutting into the HVAC ducts and replacing OEM components with generic components.

Can I replace the blend door actuator myself?

Because of the amount of disassembly that may be required, this repair is usually best left to a professional mechanic. Removing airbags and other dashboard components can be dangerous, and can leave car safety systems compromised if not handled correctly.

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JAMES AT POLY PERFORMANCE - CAN'T DO IT

On Oct 9, 2019, at 2:28 PM, James Collins <james@polyperformance.com> wrote:

Hello Tim,

I really appreciate all your emails and wanting to use us as your main stop shop for all your needs to try and bring your dream dodge to life. Unfortunately after talking with the mechanic and the manager here, a lot of these upgrades aren't really what we are looking to get our hands on such as the Engine Performance upgrades, EGT Sensors, Exhaust modifications and in locating and wiring a 2nd location for a battery.

As of now with the new mechanic we are going to keep a lot of the main custom modifications and upgrades to a minimal and stick to the more bolt-on suspension upgrades for the time being until we are able to get more time with seeing what he is capable of doing with some of the jobs we have him to do around here.

If you do want to get something done fairly soon I could recommend going to Switzer Diesel up in Santa Margarita or call Rick's Diesel Performance down in Buelton as they'll know what to do and the upgrades you'll need to get the performance you're looking for out of the motor.

Then maybe contact and talk to the guys at Drive customs here in SLO to see if they're capable of setting up your 2nd dual battery system for you. We do use them for all of our electrical needs on our shop vehicles here with back-up cameras, speaker systems, etc.

I also would love to bring your dodge in here for the ARB and Gear work, but as of now we are are sending out the new technician to Nitro-Gear to go under some training for gear work before we send him out to work on our customers vehicles.

I look forward to assisting you in the future when we are more ready and capable to do some of the custom fabrication you're looking for. If you do need any assistance in at least sourcing the parts for the job I'd at least still be happy to help you there.

Best Regards,

-James

James Collins
Customer Service Associate
Poly Performance, Inc.
870 Industrial Way
San Luis Obispo, CA 93401
805-783-2060

805-706-0367 Direct

www.PolyPerformance.com

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INTRODUCTION: Its time to finish my truck! Enough already. I contacted James at Poly Performance https://www.polyperformance.com so we could team up to finish my truck. I'll be documenting everything, and will be sparing no reasonable expense.

Thanks to Tom B. for getting my truck this far. The truck is roughly half way done. I'm a lousy mechanic, but Tom is a great one, so everything done so far is rock solid. Here's what has already been done.

ALREADY INSTALLED AND WORKING
- White Knuckle Rock Sliders
- Set of 4 Carli Ball Joints installed on all 4 Corners ($200 each!)
- Steering box brace, new tie rod and drag link
- Tuned King Shocks & Thuren Soft Coils up front
https://www.thurenfabrication.com/products/dodge-ram/2003-2013-ram-2500-and-3500/components/coils.html
https://www.thurenfabrication.com/products/dodge-ram/2003-2013-ram-2500-and-3500/components/coils/2-soft-ride-performance-coils.html
- Firestone Rear Air Bag (No Leaf Springs) Suspension
- Aluminess Front Bumper with LED Lighting
- 2 inch Hitch Receiver front and Rear for Removable Winch
- Cargo Bed Compressor
- Hill Billy Rear Bed Sleeping Platform
- 8 Carbon Fiber Switches in Overhead for Controlling All Functions

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SHOULD I SWITCH TO AMSOIL?
$250 worth of Amsoil synthetic oil (almost 4 gallons) for diffs, tranny and transfer case.
$40 to cover the gaskets for the diff oil change.
Mechanics that I trust no longer uses any synthetics in diffs due to some strange failures he’s seen in Syn filled units. Not sure about trannys and transfer cases. If “my” truck came from the factory with “regular” oil, and the manual called for “regular” oil, I’d probably stick with “regular” oil.

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TRANSFER CASE SKID PLATE: MATERIAL AT POLY PERFORMANCE
11/4/2019 - check with Poly Performance. Andy back.
A while back, Poly Performance told me they had designed and fabricated COMPLETE Dodge Cummins ski plates, and would have them available for sale. Apparently, the guys they hired to fabricate them bailed out, and they are left with cut stock that doesn't require much to get "online".
I visited Poly Performance today 10/21/2019 and they said the following:

- we will sell you the stock for these skid plates at cost (or lower I said) so that they wouldn't sit around the shop for years, then get sold for scrap
- He said to wait until Andy (Andy@polyperformance.com) gets back from vacation, and talk to him about the steel sheet stock.
- He said that Hanks Welding 805-709-3228 could finish up this nearly complete project
- He also gave me the number of Paul Michelle 619-709-3748 for reasons I cannot remember.
- There are 3 sets of these complete skid plate sets. I am only interested in the skid plate section that cover the transfer case, as this skid plate package is VERY HEAVY and front axle biased, which I don't want. The Transfer case is pretty close to the middle of the truck.

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PHASE 1: LOCOMOTION

James and I decided to start with the power train. My truck is totally stock: 5.9L High Output Cummins 325 horse power and 610 foot pounds of torque. Engine upgrades will only be to increase miles per gallon and marginal increase in power.

Here are the generic upgrades. James and his crew will pick the components that will make this happen:
- Tuner / Programmer with integrated back up camera display
- EGT and complete complement of gauges
- Air Intake System / Perhaps even a snorkel to breath less dusty air.
- RAM Air Intake system
- "Cat Back" Exhaust System and tame Catalytic Converter, perhaps.

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EXHAUST BRAKE
- Exhaust Braking 101
For those who are not familiar with exhaust brakes, the principle is very simple: Restrict the engine’s exhaust flow downstream from the turbo when the throttle is lifted so the increased backpressure works against the engine, slowing it down. It’s a great secondary braking system for trucks that tow or haul heavy loads, and it functions by hydraulically opening the exhaust valves, releasing compression during the engine’s power stroke. (They’re also known as Jacobsen “Jake” brakes, the devices you hear used in big rigs.)
An exhaust brake is just a valve in the exhaust system that partially closes when the throttle is lifted. If the exhaust is completely blocked off, some serious braking will happen. But, at the same time, the pressure that builds upstream (which can reach 60 psi) will either explode the exhaust system or do serious damage to the engine.
To ensure those types of issues don’t occur, exhaust brakes like BD’s universal device can be adjusted to limit backpressure so as to not exceed the engine builder’s specifications: The Power Stroke should not exceed 40 psi, Cummins 60 psi, and Duramax 55 psi.
- Banks Exhaust Brake for Manual Transmissions
https://s3.amazonaws.com/assets.bankspower.com/sdc/manual/97232_dodgeexhaustbrakesystem_v4.pdf

BD Diesel Performance
Sumas, WA 98295
800-887-5030
www.dieselperformance.com
https://www.dieselpowerproducts.com/c-169-20045-07-59l-dodge-cummins-exhaust-brakes-bd-pacbrake-and-banks.aspx

Dunks Performance
541-726-1006
http://dunksperformance.com/

http://www.trucktrend.com/how-to/towing/1703-how-to-install-a-bd-diesel-exhaust-brake
- Manual Transmission Exhaust Brake https://www.bankspower.com/i-299-banks-brake-exhaust-braking-system-for-2006-2007-dodge-ram-2500-3500-5-9l-cummins-manual-transmission.html

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REAR BUMPER
James found this rear Mercenary Offroad bumper.
https://mercenaryoffroad.com/components/bumpers/dodge-bumpers/rear-high-clearance-3rd.html
I love having the exhaust go through the bumper. I'm tired of flattening my exhaust tip every time I go wheeling. We will look and see if we can make this bumper work. Time will tell. Its not cheap at $2,500!!!!

https://realtruck.com/p/fab-fours-premium-rear-bumper/v/dodge/ram-2500/2008/

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MISC ITEMS

- Upgrade trailer brake controller (the manual control knob recently broke off of it).

- Fabricate storage in the tail gate for straps and recovery gear. The Dodge has a HUGE tail gate that is full of "Unused Air". Would love to have a storage panel for all that "Rescue and Recovery" Gear!