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2002 Ram 2500: Darth Vader Dodge

900hp, VP44-equipped— and Virtually Indestructible

Text By Jason Sands, Photography by Jason Sands
Darth Vader Dodge 2002 Dodge Ram 2500 Pulling Sled
With a quick switch of wheels and tires, the Dodge can move from dragstrip to sled pull trim, all within the same day.
Darth Vader Dodge 2002 Dodge Ram 2500 Pulling Sled
With a quick switch of wheels and tires, the Dodge can move from dragstrip to sled pull tr

Everybody knows drag racing and sled pulling are very hard on diesel trucks. However, not everyone knows how to make their torque-heavy diesels last under the duress of such activities. Not only is TJ Bauer one of those people who can make his truck work, he’s confident enough that he’s willing to drive for hours to local events without a trailer. Inspired by his gumption, we dove straight for our camera to take some pictures.

Darth Vader Dodge 2002 Dodge Ram 2500 Rear Three Quarter

From the Ground Up: The Chassis
TJ spent a lot of time on a few components most skim over: the axles. He reasoned that driveline breakage is a common weak link in both drag racing and sled pulling, so he started where the rubber meets the road. The front axles were upgraded to 35-spline units from Pure Diesel Power, while the rear Dana 80 received a set of 37-spline Haisley Machine axles. Detroit Lockers are also found both fore and aft, as well as 3.54 gears. A set of owner-made traction bars keeps axlewrap to a minimum, which is very important for reliability. The final step for TJ was to install heavy-duty 1480 yokes and U-joints in the driveline.

The Transmission
The transmission couldn’t be any weaker than the rest of the drivetrain, so TJ went to one of the best in the business: Dave Goerend. Goerend Transmission outfitted the 47RE with stronger 48RE internals, as well as a constant-pressure valvebody. The valvebody is kept at 180 psi all the time to ensure clutches aren’t a weak point during spooling, or on and off the throttle. The transmission also features 300M input, output, and intermediate shafts and an 1,800-rpm-stall triple-disc converter.

Darth Vader Dodge 5 9L Cummins Engine
The engine in TJ’s ’02 Dodge has been completely rebuilt and makes approximately 700 rwhp on diesel only—and more than 900 hp once the nitrous has been activated.
Darth Vader Dodge 5 9L Cummins Engine
The engine in TJ’s ’02 Dodge has been completely rebuilt and makes approximately 700 rwhp

The Engine
There’s a reason the entire truck was built to handle gobs of power and torque, and it’s the 903-rwhp and 1,630-lb-ft dyno sheet that makes the reason a bit clearer. The engine was completely rebuilt, with 0.020-inch-over pistons, as well as main stud and rod bolts from Pure Diesel Power. A Hamilton Cams 188/220-degree camshaft was used as well, along with 110-pound springs. The engine also features an owner-ported common-rail head, which helps flow more air and keeps boost pressures mellow. Up top, a set of ARP 625 studs and a fire-ringed head make sure the engine’s coolant stays put. Rounding out the potent package is an S466 turbo, Industrial Injection fuel system, and Nitrous Express nitrous system.

Built to Drive
TJ isn’t scared to put his well-engineered setup to the test by driving three, four, or even five hours away from home to drag race or sled pull. With a best quarter-mile time of 11.90 seconds at 113 mph without nitrous and multiple sled pulls under his belt (not to mention 18 mpg), we’d say this Dodge is one tough competitor.

  • Darth Vader Dodge Injection Pump
    The 5.9L Cummins features a pretty wild injection system, including a modified VP44 pump, oversized lines, and 6x0.016-inch injectors from Industrial injection. A FASS 150-gph lift pump feeds it all.
    Darth Vader Dodge Injection Pump
    The 5.9L Cummins features a pretty wild injection system, including a modified VP44 pump,
  • Darth Vader Dodge Front Dana 60 Axle
    The front Dana 60 axle is now a 35-spline unit and also houses a Detroit Locker. So far, it has held up to the abuse that has been thrown its way.
    Darth Vader Dodge Front Dana 60 Axle
    The front Dana 60 axle is now a 35-spline unit and also houses a Detroit Locker. So far, i
  • Darth Vader Dodge Spearco Intercooler
    A mammoth Spearco intercooler helps keep discharge temperatures within reason, again, making the setup all the more durable.
    Darth Vader Dodge Spearco Intercooler
    A mammoth Spearco intercooler helps keep discharge temperatures within reason, again, maki
  • Darth Vader Dodge 66Mm Turbocharger
    The turbocharger on the Cummins is an S400-based 66mm charger, complete with a BatMoWheel upgrade. With the wastegate blocked on the Steed Speed manifold, TJ sees 55 psi with the skinny pedal all the way down.
    Darth Vader Dodge 66Mm Turbocharger
    The turbocharger on the Cummins is an S400-based 66mm charger, complete with a BatMoWheel
  • Darth Vader Dodge Arp 625 Head Studs
    The ARP 625 head studs and fire-ringed common-rail head are integral parts of the engine build and greatly increase the reliability of the top end of the engine.
    Darth Vader Dodge Arp 625 Head Studs
    The ARP 625 head studs and fire-ringed common-rail head are integral parts of the engine b
  • Darth Vader Dodge Nitrous Bottle
    An NXD4000 nitrous kit is used to make big power on the dyno, and during the occasional sled pull (when allowed).
    Darth Vader Dodge Nitrous Bottle
    An NXD4000 nitrous kit is used to make big power on the dyno, and during the occasional sl
  • Darth Vader Dodge Bed Mounted Transmission Cooler
    Transmissions hate heat, and dual ATF coolers with fans are mounted in the bed of the truck to keep transmission temperatures under control. Even with constant full-throttle blasts, the fluid rarely goes beyond 160 degrees.
    Darth Vader Dodge Bed Mounted Transmission Cooler
    Transmissions hate heat, and dual ATF coolers with fans are mounted in the bed of the truc
  • Darth Vader Dodge 7 Inch Exhaust Stack
    Maryland Performance Diesel helped build the intake and exhaust piping, which ends in a 7-inch stack.
    Darth Vader Dodge 7 Inch Exhaust Stack
    Maryland Performance Diesel helped build the intake and exhaust piping, which ends in a 7-
  • Darth Vader Dodge Auto Meter Gauges
    TJ keeps an eye on his vitals thanks to an A-pillar’s worth of Auto Meter gauges, which measure boost, EGT, and fuel pressure.
    Darth Vader Dodge Auto Meter Gauges
    TJ keeps an eye on his vitals thanks to an A-pillar’s worth of Auto Meter gauges, which me
  • Darth Vader Dodge Rear Dana 80 Axle
    The rear Dana 80 axle was equipped with a Detroit Locker and 37-spline axles for ultimate reliability.
    Darth Vader Dodge Rear Dana 80 Axle
    The rear Dana 80 axle was equipped with a Detroit Locker and 37-spline axles for ultimate
  • Darth Vader Dodge Rear Traction Bar
    A custom set of traction bars was built to keep the pinion pointed in the right direction.
  • Darth Vader Dodge 2002 Dodge Ram At The Drag Strip
    At the dragstrip, TJ’s Ram clicks off high-11-second quarter-mile times. Not only should a little nitrous help with the elapsed time, but it will probably also lower the 1,600-degree exhaust gas temperatures the Dodge sees going through the lights.
    Darth Vader Dodge 2002 Dodge Ram At The Drag Strip
    At the dragstrip, TJ’s Ram clicks off high-11-second quarter-mile times. Not only should a
By Jason Sands
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