How to Make 450-500hp On a 3rd Gen Cummins RELIABLY

In this video I walk you through everything you need to make 500hp on a 3rd Gen Common rail Cummins Ram truck reliably. Follow along as I go through the full parts list from the custom EFI live tuning, to the head studs, Fass, and transmission upgrades.

While lots of places will give you a general idea, this is the complete list to do it the RIGHT way!

The Parts List:

Tuning ( Custom EFI live from NRE Performance)

ARP 625 Head Studs:

Transmission:

Stage 1-2 Automatic:

Valair Dual Disc Organic (Quiet) Clutch:

Hamilton 103lb Valve Springs:

Hamilton HAM07-P-004 Push Rods

Fass 100 Lift Pump:

Edge Insight CTS3 Gauges:

#cummins #3rdgencummins #500hp

[northridgenation]

Having the patience to take the time to build rigs the right way is always worth it. Nice work, Andrew!

[Feilo]

Valve springs help with boost blowing the valves open on a diesel. Most people don't spin them that much faster than stock to worry about floating the valve train. Push rods make sense if you stiffen the springs but critical if you have an aggressive cam. Agreed that lift pump, head studs, and transmission are a must. The Fleece bypass is what I will install when I replace my clutch.

[adamroos]

Just got my 2004.5 Cummins a few days ago and people make then sound sluggish stock but truck came with a 4" exhaust and S&B intake installed and I think it rips really good stock. I wanted a 650 HP truck but having finally driven one I think 400-500 is I'll be able to save a lot of money only doing 400-500 HP vs 650 now :D

[ChaosViper]

Even though I don't agree with everything in your vids, you gave the highest quality and knowledgeable content online. Always interesting to watch. Keep it up man.

[LMDiesel]

Great build list! I basically have all the same stuff on my 3rd gen! Let me know when you get tired of 500hp tho 😁 I got a great recipe for 800hp to 1000hp!

[LCO]

Andrew, another awesome video. What a beautiful truck you have created. Great advice for a solid tune that will support reliability and power. I love my 03 HO with many of the reliable mods you talk about. Many thanks to your thoughtful knowledge. Patrick

[adamw.]

my 06' 5.9 dyno'd 426hp/898tq on just a bullydog GT tuner at max tune, with a straight pipe exhaust. Really doesn't take much with these trucks!

[subjectoriginal]

How clean this truck in blows my mind everytime especially the engine bay

[klaus]

First upgrade I did was all new front suspension: linkage upgrade, shocks, ball joints, and replaced the collapsed coil springs. Followed by the egt/trans/boost gauge because I tow every weekend. Then for an additional 5hp and 10 ft. lbs. of torque I slapped on a South Texas Low Fence Hunting sticker. lol

[adamhenton]

New video = I click

Your channel gives us so many great ideas. Thanks for the awesome content.

[mxerb]

I have all the bolt ons and firepunk stg 2 trans with edge tuning due to being an 04 and on level 5. An sti was tailgating me and when we lined up at a light he couldn’t get by until 110 😂 would have like to see the look on his face. Want compounds some time.

[traviswestlee]

that is one clean 3rd gen! nice job man

[baileysavage]

Awesome info! Would love to see you cover the same information about duramax and powerstroke in the future!

[anthonykaiser]

I had a white '99 1500 that was that nice. Almost. I was the 2d owner, and Dad knew the first one. CR regarded that year as best of BRs. Almost. I clay barred it, and it literally glowed. It had the Driftwood lower quarter panel and Laramie SLT trim, with a 318, Quad Cab 4x4. More comfy than my 05 2500.

[williamroberts]

I have a 2012 with 3.5" banks boost tubes, banks intercooler, Banks monster ram with plate and grid heater relocation. Banks ram air cold air intake. I took out the thermostatically controlled valves on the transmission lines. It also is tuned. 4:10 gears. What a difference just those modifications made. I average about 22mpg around town. I love the truck now its like a totally different truck now. Its on 35x12x20 tis 547 and Mickey Thompson Baja boss A/T's. The truck goes pretty good

[danal]

Appreciate the clear cut info as always my guy. Cheers!

[kuhndog-]

I like seeing a guy that is happy about not seeing smoke lol. I personally decided to go the 6.4 hemi route in a 3/4 ton but now I'm looking into doing a g56 swap on the truck. Mechanically the g56 should fit and the swap will be similar to a cummins however I will need to make new fuel lines. The factory lines go over the transmission right where the g56 shifter would go through the floor. Did you know that before the lines cross over the trans the are plastic? Cost cutting at it's finest I guess.

[dieseldemon]

One note to add, I’m not sure what you are seeing for consistent manifold pressures, but I was seeing consistent 27-32 psi under load.
This isn’t much, but it was enough to cause my stock intercooler to leak.
I’m not sure if mine was just a fluke- as I’ve seen them handle much more abuse and survive, but fwiw, I’d consider an upgraded intercooler and boots a worthwhile investment as well.

[PlaneSaddles]

Early 04 305hp Cummins 6spd. My plan has always been about the same as you for the support mods, minus the valve work (I don't hardly push 2500rpm), but the power addatives are going to be hardware in the forms of mild turbo, injectors, and the minimalist of tunes.
Have had the truck 19 years and still not very far into the list. Lol

[josuemiranda]

Roll the windows down more, I love this video!! Great stuff!! 🍻🙌🏽🤠