| 2006 Dodge Ram Megacab engine
The only way to tell whether we made the right choices was to add a sampling of performance products in a logical order, run the truck on a dyno between each modification, and examine the numbers. For this test, we chose experienced companies with products that fit our needs. The Ram was to be a daily driver, not a dragster--its manners had to remain intact as well as its long-term reliability.For all modifications and subsequent tests, a calibrated Mustang dynamometer was used. Note that all dynamometers don't read the same. Factors such as altitude, ambient temperature, humidity, and the specific programs being used on a given dyno on any given day have to be considered. The actual numbers are just that: numbers to be compared with other numbers derived from similar conditions. Your results may vary.
| Corsa's Reflective Sound Cancellation technology allows Corsa to tune out the undesirable low frequencies that cause droning.
After discussing the project with several diesel experts, we started with the air intake and exhaust. While we didn't expect huge gains from these components, a diesel engine needs to breathe, so the functions of these items would come into play later. A baseline test came first: on the dyno, our stock truck showed 265 horsepower and 505.8 pound-feet of torque, as we expected.
In phase one, we installed a Corsa Performance exhaust, a straight-through, nonrestrictive system. Using 304 stainless-steel four-inch-diameter mandrel-bent tubes, it's said to provide a 47-percent gain in exhaust flow over stock. That means lower exhaust gas temperatures (EGTs) and improved horsepower and torque. But Corsa's Reflective Sound Cancellation technology, which allows the company to tune out the undesirable low-frequency sounds that cause droning at speed, is a huge plus.
| S&B's cold-air intake kit claims to flow 40.2 percent more air than stock. We like that the custom airbox has a clear inspection window.
After installing the exhaust and hydroformed four-inch oval stainless-steel tip, the Ram went onto the dyno. Horsepower increased to 268.9 and torque to 513.8. That's not a huge difference, but the Ram's got a great deep throaty sound when you tromp on it. The complete cat-back kit lists for $953.99.
Next came an S&B cold-air intake kit that's said to flow 40.2 percent more air than the factory system. We like the easy installation, huge eight-layer gauze/mesh filter, and custom airbox. It even has an inspection window. With this system, horsepower increased to 269.1 and torque was measured at 513. Again, that's not a huge difference, but the superior airflow of the S&B Filter will be essential later on, especially with lower EGTs. The performance intake kit lists for $194.61.
| The ATS ARC Flow intake creates a smooth path for the air. More air means more oxygen, and that means more efficient combustion.
As the cooled air exits the intercooler, the next restriction in the factory system is the intake manifold. By installing the ATS ARC Flow intake, a smoother path for the air to follow was created. More air means more oxygen, and that means more efficient combustion. The ARC Flow allows the air to expand at a rate that doesn't create turbulence as the air is fed into the cylinder heads. The ARC Flow also comes pre-tapped for accessories, including water injection and boost gauge. A turn on the dyno demonstrated horsepower up to 275.8 and torque at 526. The ATS ARC Flow intake goes for $396.
The engine was breathing better, but the improvements were still nothing to jump up and down about. Ken (our expert at Ken Imler Diesel Performance) pointed out that while the dyno numbers weren't huge, intake and exhaust modifications typically produce as much as 20 horsepower under a real load, like hauling a heavy trailer up a steep grade, again because both will significantly reduce the EGT.
| 2006 Dodge Ram Megacab exhaust
Digging still deeper in our pockets, we exchanged the factory turbo and exhaust manifold for the ATS Aurora 2000 and an ATS Multi-Piece Pulse Manifold. The Aurora 2000 has a huge compressor housing providing massive air volume, and there's no wastegate, so all the available hot exhaust gases coming out of the engine are spinning the turbine. EGTs are lowered, and boost pressures typically run between 32 and 38 psi, with quick off-the-line and midrange response. Great fun for a daily driver.
The hot exhaust exiting the combustion chambers must flow unrestricted through the exhaust manifold to spin the turbocharger's turbine. ATS has engineered a pulse exhaust-flow design, helping spool up the turbocharger fast with less exhaust backpressure and increase fuel efficiency. And the manifold was pre-tapped for our pyrometer probe. Back on the dyno, the Ram was starting to show impressive results. Horsepower climbed to 275.8, and torque rose to 526. The ATS Aurora 2000 runs about $1664.25, and the ATS Multi-Piece Pulse Manifold will set you back $493.50.
Plenty of air was getting into the engine, but not much fuel. The Edge Juice with Attitude is a computer that interfaces with the factory electronics. There are selectable audio alerts for EGT, speed, boost, and engine and transmission temperatures. Features of the Juice with Attitude include defueling during shifts, defueling during transmission slip, and defueling during TCC lock-up. The backlit digital screen, which mounts on the dash, shows corrected speed by taking into account changes in tire size and axle ratio.
| 2006 Dodge Ram Megacab Auto Meter Gauges
| 2006 Dodge Ram Megacab EDGE Display
| The two-piece ATS Pulse Manifold design eliminates the problems with shrinking, breaking, and the risk of cracked gaskets.
The Attitude screen displays all the information that a set of gauges would and more, including RPM, boost, EGT, 0-60 and quarter-mile times, transmission slip, percentage backdown, torque converter slip percentage (and when the torque converter's locked), load and throttle percentages, turbo cooldown timer, and transmission-fluid, intake air, and engine-coolant temperatures. It also can display and clear trouble codes and will even show barometric pressure. The Edge Juice with Attitude for the Dodge lists for $999.
In our quest for performance, we could select on the fly from five adjustable power levels for 25, 40, 60, 80, or 100 extra horsepower, or even 160 more with the Hot Juice Upgrade. (Hot Unlock Code required for level six--to get the unlock code you must complete a waiver located under product updates on Edge's Web site.) The Edge Juice with Attitude takes about 30 minutes to install.
| The ATS Aurora 2000's significantly larger compressor housing (L) provides massive air volume, and there's no wastegate--all available hot exhaust gases coming out of the engine spin the turbine.
Even though the Edge Juice was telling the injection system to add more fuel at higher settings, we were actually running out of fuel: the factory pump couldn't keep up. We needed an FASS high-performance fuel delivery system.
The FASS system would accomplish two important things. Its high-performance pump would supply a constant volume of diesel (over three times more than the OEM pump). Second, its dual filters remove air from the fuel. Diesel, like any liquid, doesn't compress well. Air, on the other hand, is easy to compress. Think about the last time there was air in your truck's brakelines. Even a small amount of air in the fuel is enough to cushion and consequently delay the opening of the injectors, which disrupts the timing of the whole electronically choreographed dance. The FASS sells for $684.
| Diesel Performance's FASS high-performance fuel-delivery system comes with all hoses and connections.
Back on the Mustang, results were looking impressive. The Dodge's horsepower soared to 337.7 in the #3 (Drive) setting. Torque climbed to 666.4. In the #5 (Race) setting, horsepower jumped to 365.3 and torque to 724.8. In the Hot Juice upgrade setting, we saw another jump to a tire-smoking 403.1 horsepower and 766.1 pound-feet of torque and, because of the balanced system, EGTs remained under control and black smoke was surprisingly minimal.
A seat-of-the-pants road test served to verify the dyno numbers. We didn't use the Hot Juice level on the street, but even in the #3 (Drive) setting, the combination of all the modifications were amazing. Accelerating from 60 mph to over 80 gave us the feeling of an afterburner kicking in. It just kept pulling! We strongly recommend using cruise control and keeping a watchful eye on the rearview mirror.
| Proper installation of the FASS requires dropping the main fuel tank to install the special pick-up tube. The twin filters of the FASS high-performance fuel-delivery system remove all contaminants including water and air.
The lesson here is clear: Power is the sum of all parts. You can pump cold air through a diesel 'til you're blue in the face, with little gain in performance. Air by itself doesn't burn. You can dump gallons of fuel into the engine, but without the correct amount of air, all you'll get is black smoke, and probably a ticket, too. But add the right balance of air and fuel and the potential increase of horsepower and torque is impressive.
What about fuel economy? Realistically, if you have 25, 40, 60, 80, 100, or even 160 extra ponies under your foot, you're most likely going to use them, right? And that doesn't make for better mileage.
Now the obvious question: What does that extra power do to manufacturer warranties? Legally, thanks to the Federal Magnusson-Moss Warranty Act, a dealer must honor your warranty unless it can be proven that the specific modifications were the direct cause of the problem. That said, some dealers will use the presence of any aftermarket products to void a warranty entirely. Performance chips can be quickly disconnected and removed before bringing your vehicle into a dealer for any warranty work; that ensures no interference with the technicians' diagnostic equipment. Simply removing the module will restore all factory settings.
Obviously, dragging a heavy load up a grade in Level 5 (Extreme or Hot Juice) isn't a good idea, even though most computers like the Edge will defuel when the EGTs reach a preset danger level. To keep visual tabs on boost, EGT, and transmission temperature, we installed a set of Auto Meter gauges in one of the company's pillar pod kits. The white Phantom collection matches the factory Ram gauges.
| 2006 Dodge Ram Megacab graph
Finally, it's always important to drive sensibly. Using the higher settings of a performance product can place extreme loads on your transmission as well as on other links in your powertrain chain. If you're planning on going the full power route, it's wise to include some transmission upgrades before all that torque bites you in the wallet.
What We Added HP Torque +/- hp/lb-ft CostBaseline 265.0 505.8 --- ------Corsa exhaust 268.9 513.8 +3.9/+8.0 $954S&B cold-air intake 269.1 513.0 +0.2/-0.8 $195ATS ARC flow kit, Aurora/Pulse 275.8 526.0 +6.7/+13.0 $2554FASS, Edge Juice with Attitude--Drive. 337.7 666.4 +61.9/+140.4 $1683Race 365.3 724.8 +27.6/+58.4 Hot Juice 403.1 766.1 +37.8/+41.3 Totals: 403.1 766.1 +138.1/+260.3 $5386
| To keep visual tabs on boost, EGT, and transmission temperature, we installed a set of Auto Meter gauges in a pillar pod kit.
| 2006 Dodge Ram Megacab burnout
| 2006 Dodge Ram Megacab corsa Exhaust
| 2006 Dodge Ram Megacab
| 2006 Dodge Ram Megacab logos
| 2006 Dodge Ram Megacab money
| 2006 Dodge Ram Megacab dyno
| 2006 Dodge Ram Megacab dyno
| 2006 Dodge Ram Megacab dyno
| 2006 Dodge Ram Megacab engine
