Gatordoc
Adventurer
EDIT: Pics can be found HERE
2003 Dodge 2500 Quad Cab, Short bed
Cummins Powered, Standard Output
47RE Automatic Transmission
NP271 (I think???) Floor shift, part time transfer case
4.10 Geared axles
10.5 AAM rear Axle w/torsen limited slip
I bought this truck in the fall of 2008 with 55k on the clock, it now has ~115 and is still basically bone stock. The mileage is getting to the point where I know the axles, transmission, and a few other things are about due for some preventative maintenance so I am planning to upgrade a few things while I'm in there.
I recently purchased my first brand-new vehicle, a 2011 Triumph Tiger 800, which I will be commuting on unless circumstances require the truck for some reason so I am planning to work on things in increments, a couple days or a weekend at a time, rather than try to do everything at once.
I am going to lay it all out here on the thread, hopefully you guys will chime in with suggestions and/or constructive criticism on my plans. It's essentially brainstorming at this point, so please feel free comment away.
The first stage is going to be pretty much straight PMCS, as follows:
Rear axle service
- Brakes
brake pads
shoes
turn or replace rotors
- Replace axle seals
- Check wheel bearings
- New, High capacity diff cover (Suggestions???)
- Fresh synthetic gear oil
Front axle service
- Brakes -DONE
brake pads -DONE
turn or replace rotors -DONE
- Replace axle seals -DONE
- Replace Knuckle universals (HD replacement???) -DONE
- Replace upper/lower ball joints (HD replacement???)
- Fresh synthetic gear oil -DONE
- Inspect/Replace tie rod ends (08+ upgrade, if budget allows)
- Adjustable Thuren track bar
- Alignment
- Traction aid if budget allows (Suggestions???)
Transmission Service
- Replace leaking front seal
- Drain/replace fluid
- Replace filter
- Deep sump pan (Suggestions???)
- Shift kit (Suggestions???)
Engine Service
- Replace leaking valve cover gasket
- Adjust valve clearance
- Test, clean, balance injectors (North County San Diego shop suggestions?)
- Replace accessory belt
- Replace exhaust (turbo back)
Stage two will focus on improving performance on/off road for general exploring. I am not looking to build a specialized, off-road beast, just something capable of getting my wife and I and a munchkin or two away from civilization for a few days and back safely.
Performance
- FASS/airdog/whoever fuel pump w/canister filters.
- That's it, the engine and transmission will remail BONE STOCK for reliability.
- Turbo back exhaust
- Air Filer/snorkel upgrade
Tires
The truck needs tires - right now, right now. Fortunately the 3rd gen Dodges have huge wheel openings and will fit 37s on stock rims with little/no rubbing. What flavor, that's the question… I know I want an aggressive tire, but it needs to have decent wear characteristics and be able to support pulling a 5-6k travel trailer for local (200-300 mile max) trips until I am able to (convince the wife to let me) sell it and get into a flip-pac (stage three).
I have always had good luck with BFGs in the past and the stock rugged trails have held up impressively well for the abuse I've given them. I have also heard very good things about Nittos, but don't have personal experience. Suggestions???
Suspension
I want to lift the truck as little as possible, 2-3 inches, while improving on/off road performance. This jives well with Thuren/Lorenz/Carli products, so that shouldn't be too difficult. When it comes time to buy I will have to call around and see what they recommend, but I've heard nothing but good things about all of these companies so I don't think I can go wrong with any of them. For my needs likely I will stick with just springs, shocks, and sway bar links. The rear will get mini-packs or maybe reworked packs with airbags for adjustability/leveling. I am tentatively planning on entry level re-buildable shocks, but not sure what brand yet. Buy once, cry once, right?
Protection
ARB front winch bumper – it's the most economical bull bar I have been able to find for the Dodge trucks at $1500 +/-, I like how it looks, and ARB has a fantastic reputation. It's also not GIGANTIC like many of the ranch-style HD truck bumpers.
Sliders/steps and skids will have to be custom made, hopefully by myself as I have access to a metal shop and experienced welders through work. I'll look into the MOPAR Power Wagon skids, but I have a feeling those will be difficult to find and I have honestly been unimpressed with the photos I've seen, other than the unobtainium sliders.
Misc
Bedlined rockers – this is a must as I will eventually end up back in Michigan and I want to keep the cancer at bay as long as possible. I'll do this myself, I was a professional industrial painter before I joined the Corps so I know all about proper prep. I will also be going over the undercarriage with some type of rust inhibitor, POR15 or similar, before moving back to the rust belt.
Stage three is long term plans to gradually convert the truck into an essentially self contained backwoods camper. This is a very flexible wish list so please feel free to comment; I prefer to learn from OTHER people's mistakes rather than make them myself, if I can help it.
AT Flip-Pac – I would prefer to have this purchased and installed before I leave the south west, but my budget and other factors will dictate if this actually happens or not. I like these for the same reason everyone else on this board does; it's a simple, sleek design that is relatively light weight and extremely flexible.
Fiberglass utility/service bed OR flat bed with permanently attached tool boxes – in my head this is the perfect accompaniment for a flip pac or slide in camper, though I have been known to be wrong once or twice in the past. Thoughts?
Fresh water – 10-20 gallon capacity, located where the spare tire currently lives? Shore hookups installed in outside of truck body
House battery(ies) with solar, charge controller, and shore hookups
Fridge/freezer
Cassette toilet
Water heater w/outside shower enclosure (gotta keep the wife happy)
Awning w/enclosure walls for shower / changing room / extra sleeping for guests/kids
That's basically it, in a nut shell. I will be posting photos and updating this thread as I get things done over the next few months, provided can keep myself from getting distracted by the new bike. :bike_rider:
Cheers! :beer::beer:
2003 Dodge 2500 Quad Cab, Short bed
Cummins Powered, Standard Output
47RE Automatic Transmission
NP271 (I think???) Floor shift, part time transfer case
4.10 Geared axles
10.5 AAM rear Axle w/torsen limited slip
I bought this truck in the fall of 2008 with 55k on the clock, it now has ~115 and is still basically bone stock. The mileage is getting to the point where I know the axles, transmission, and a few other things are about due for some preventative maintenance so I am planning to upgrade a few things while I'm in there.
I recently purchased my first brand-new vehicle, a 2011 Triumph Tiger 800, which I will be commuting on unless circumstances require the truck for some reason so I am planning to work on things in increments, a couple days or a weekend at a time, rather than try to do everything at once.
I am going to lay it all out here on the thread, hopefully you guys will chime in with suggestions and/or constructive criticism on my plans. It's essentially brainstorming at this point, so please feel free comment away.
The first stage is going to be pretty much straight PMCS, as follows:
Rear axle service
- Brakes
brake pads
shoes
turn or replace rotors
- Replace axle seals
- Check wheel bearings
- New, High capacity diff cover (Suggestions???)
- Fresh synthetic gear oil
Front axle service
- Brakes -DONE
brake pads -DONE
turn or replace rotors -DONE
- Replace axle seals -DONE
- Replace Knuckle universals (HD replacement???) -DONE
- Replace upper/lower ball joints (HD replacement???)
- Fresh synthetic gear oil -DONE
- Inspect/Replace tie rod ends (08+ upgrade, if budget allows)
- Adjustable Thuren track bar
- Alignment
- Traction aid if budget allows (Suggestions???)
Transmission Service
- Replace leaking front seal
- Drain/replace fluid
- Replace filter
- Deep sump pan (Suggestions???)
- Shift kit (Suggestions???)
Engine Service
- Replace leaking valve cover gasket
- Adjust valve clearance
- Test, clean, balance injectors (North County San Diego shop suggestions?)
- Replace accessory belt
- Replace exhaust (turbo back)
Stage two will focus on improving performance on/off road for general exploring. I am not looking to build a specialized, off-road beast, just something capable of getting my wife and I and a munchkin or two away from civilization for a few days and back safely.
Performance
- FASS/airdog/whoever fuel pump w/canister filters.
- That's it, the engine and transmission will remail BONE STOCK for reliability.
- Turbo back exhaust
- Air Filer/snorkel upgrade
Tires
The truck needs tires - right now, right now. Fortunately the 3rd gen Dodges have huge wheel openings and will fit 37s on stock rims with little/no rubbing. What flavor, that's the question… I know I want an aggressive tire, but it needs to have decent wear characteristics and be able to support pulling a 5-6k travel trailer for local (200-300 mile max) trips until I am able to (convince the wife to let me) sell it and get into a flip-pac (stage three).
I have always had good luck with BFGs in the past and the stock rugged trails have held up impressively well for the abuse I've given them. I have also heard very good things about Nittos, but don't have personal experience. Suggestions???
Suspension
I want to lift the truck as little as possible, 2-3 inches, while improving on/off road performance. This jives well with Thuren/Lorenz/Carli products, so that shouldn't be too difficult. When it comes time to buy I will have to call around and see what they recommend, but I've heard nothing but good things about all of these companies so I don't think I can go wrong with any of them. For my needs likely I will stick with just springs, shocks, and sway bar links. The rear will get mini-packs or maybe reworked packs with airbags for adjustability/leveling. I am tentatively planning on entry level re-buildable shocks, but not sure what brand yet. Buy once, cry once, right?
Protection
ARB front winch bumper – it's the most economical bull bar I have been able to find for the Dodge trucks at $1500 +/-, I like how it looks, and ARB has a fantastic reputation. It's also not GIGANTIC like many of the ranch-style HD truck bumpers.
Sliders/steps and skids will have to be custom made, hopefully by myself as I have access to a metal shop and experienced welders through work. I'll look into the MOPAR Power Wagon skids, but I have a feeling those will be difficult to find and I have honestly been unimpressed with the photos I've seen, other than the unobtainium sliders.
Misc
Bedlined rockers – this is a must as I will eventually end up back in Michigan and I want to keep the cancer at bay as long as possible. I'll do this myself, I was a professional industrial painter before I joined the Corps so I know all about proper prep. I will also be going over the undercarriage with some type of rust inhibitor, POR15 or similar, before moving back to the rust belt.
Stage three is long term plans to gradually convert the truck into an essentially self contained backwoods camper. This is a very flexible wish list so please feel free to comment; I prefer to learn from OTHER people's mistakes rather than make them myself, if I can help it.
AT Flip-Pac – I would prefer to have this purchased and installed before I leave the south west, but my budget and other factors will dictate if this actually happens or not. I like these for the same reason everyone else on this board does; it's a simple, sleek design that is relatively light weight and extremely flexible.
Fiberglass utility/service bed OR flat bed with permanently attached tool boxes – in my head this is the perfect accompaniment for a flip pac or slide in camper, though I have been known to be wrong once or twice in the past. Thoughts?
Fresh water – 10-20 gallon capacity, located where the spare tire currently lives? Shore hookups installed in outside of truck body
House battery(ies) with solar, charge controller, and shore hookups
Fridge/freezer
Cassette toilet
Water heater w/outside shower enclosure (gotta keep the wife happy)
Awning w/enclosure walls for shower / changing room / extra sleeping for guests/kids
That's basically it, in a nut shell. I will be posting photos and updating this thread as I get things done over the next few months, provided can keep myself from getting distracted by the new bike. :bike_rider:
Cheers! :beer::beer:
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