The Total Package - Part 2

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In the last installment, we commenced a series of mods on our '03 Cummins-powered Dodge Ram using products from BD Diesel Performance. Our goal with this project is threefold: Increase the engine's horsepower and torque, address transmission performance and longevity issues and enhance overall driveability while hauling or towing heavy loads.

You'll recall that we contacted BD and asked the folks there to recommend a few upgrades that would help us achieve our goals. They recommended so many cool items we had to split our story into two parts. The first part included the installation of BD's free-flowing X-intake airbox and Maxflow exhaust, Turbo Mount Engine Exhaust Brake and nifty A-pillar mount X-Monitor with Cool Engine Shutdown option. This month we complete the upgrades by installing BD's EZ Tow Pro, X Converter, Deep Sump transmission oil pan and Tow Loc.

The guys at Attitude Performance in Arlington Heights, Illinois completed the mechanical side of these installations, while the wiring gurus at D&R Customs in Carol Stream, Illinois completed the electrical wiring of the Tow Loc.

Once we removed the transmission...        read full caption Once we removed the transmission from our Ram, swapping the stock torque converter for the new X Converter was quick and painless. The only important step to remember when installing the new torque converter is to make sure that it's filled with two quarts of transmission fluid prior to seating it on the input shaft.

Installation of the BD Deep...        read full caption Installation of the BD Deep Sump cooling pan is quick and easy. Simply remove the stock pan, clean the surface on the transmission where the new pan will mount, install the new gasket on the new pan and mount the pan and gasket to the transmission.

The EZ Tow Pro module is a...        read full caption The EZ Tow Pro module is a plug-in module that simply connects between the MAP sensor and the fuel-pressure sensor. Since it's completely sealed, it can be mounted under the hood. We mounted ours on top of the underhood fuse box using a chunk of Velcro. The Tow Pro comes with a new easy-to-install elbow that mounts on the turbo and helps to increase boost and lower exhaust gas temperature.

We mounted our Tow Loc transmission control module under the dash next to the control module for the previously installed X-Monitor. The module itself is weather-resistant so it can be mounted underhood, if you wish. The installation instructions guide you through the 10 to 12 electrical connections that provide control and sensing. The other major component of the Tow Loc is the dash-mounted switch, which we mounted to the right of the steering column.

What we Installed
EZ Tow Pro module
This easy-to-install module plugs inline into the MAP sensor and the fuel-pressure sensors. Users can adjust the module to increase rear-wheel horsepower by 30, 45, 60 or 70. This changes torque numbers by 90, 110, 160, or 210 lb-ft, respectively. This module comes with an easy-to-install new elbow that mounts in place of a stock elbow at the turbo. It has an internal orifice that delays the opening of the waste gate and adds up to 8 pounds of boost. BD says that this delay helps to lower exhaust gas temperature by 50-75 degrees.

X Converter
Designed to be a significant upgrade over the stock torque converter, this new unit sports a number of beefy features, including a stator that's machined from a solid chunk of aluminum. The stator features fin length, angle and curvature designed to meet the torque of the Cummins engine. A new double-clutch-surfaced piston was designed to replace the stock single-clutch surface to meet the engine's torque. It can handle up to 1,400 lb-ft.

Deep Sump transmission pan
Made from 356 T6 cast aluminum, these pans boast increased strength over the stock units resulting in prevention of the transmission case flexing from high torque. Additionally, the pan increases oil capacity to assist in keeping oil temperature at a proper operating level and the external cast fins are machined to help keep the contained oil cooler.

Tow Loc
This device monitors vehicle and engine speed, as well as engine load, to compute the optimum transmission control algorithm. Some of its many features include a programmable automatic 4th- to 3rd-gear downshift, vehicle speed calibration and control of torque converter lockup clutch engagement speed to prevent low vehicle speed chugging when the torque converter is locked up. When used with BD's exhaust brake, the Tow Loc offers a number of controls, including engine-brake disengagement speed to reduce noise and engine load at idle, and an engine-temperature-controlled exhaust-brake warm-up feature. A dash-mounted switch allows the user to select AutoLoc (engages clutch lockup and brake at will until rpm and/or speed has dropped below set parameters), Torqloc (commands clutch lockup), UnLoc (prevents clutch lockup) or stock (operation of clutch lockup, transmission circuit and exhaust brake are turned off).

So, How Does It Work?
Before we started with our installations, we put our Dodge Ram through a battery of tests. After we installed the BD items, we duplicated those tests to gauge what benefit, if any, we gained. All on-road testing was done while pulling a dual-axle trailer with our Project Fiery Redhead Ford F-150 lashed onto it. The total weight of the towed pair was more than 6,000 pounds. Our testing was gritty, real-world style using a GPS to track speed and a stopwatch to track elapsed time. The results were exciting. But let's back up a bit. Even before final testing began, it was clear that the BD mods had a significant impact on the big Dodge's performance because the truck exhibited improved acceleration throughout the rpm band; also, fuel mileage had improved by approximately 4 mpg.

We like the way BD addresses transmission function and durability instead of just concentrating on making gobs of engine power. We also like the Cool Engine Shutdown feature, though we're still getting used to removing the ignition key and having the engine continue running until the turbo cools.It's important to note that these test results are provided to illustrate our truck's before-and-after performance. They're probably specific to this vehicle because of our testing location, the ambient temperature and altitude, our vehicle's modifications and so on. So your results may vary.

The Total Package - Part 1