First off - I want to thank everyone on this forum for your insight, help and comments - they were very helpful and spot on. The delete was a huge success on our stock 2014 3500 3:73 68R with 173,000 miles. Total cost to do everything was under $2500 with tuner and tune. We did the work ourselves (guessing it would be ~$3000 outside shop labor?). Dealer quoted estimate of $10,000 starting point for stock configuration repair, so we saved $7500 plus the truck will hopefully go the distance without that EGR.
We have driven the truck with the mods just over 6500 miles, average 95-105F outside temps, 50% rolling/flat 50% mountains, Avg. tow speed 70mph, Avg. total weight 38,000#. I will do this to every Ram 6.7 I own as soon as they are out of warranty - fuel savings alone will pay for it (~$8k over 100k miles)!
What was done
Gutted stock DPF SCR, cleaned stock holset turbo, calibrated actuator, installed EGT probe, replaced all exhaust gaskets, blank off plates between manifold and EGR cooler (1/8" 316SS), MM3 tuner with 30HP DRD tow tune. Checked Valve clearances - were perfect at 10 &20.
Results
Mileage towing heavy has improved from 7.5mpg to 9.5-10mpg (fuel cost from .43/mile projected to .35/mile - nice!)
Mileage towing empty 10,000 trlr# went from 9 to 11 average 12 on flat ground
Increased throttle response and better pickup from a dead stop - this was the most noticeable difference
Trans shifts in lower gears are perfect! - I hear complaints they are too harsh but perfect for us.
Engine braking restored to new - was only giving us about 60% HP braking right before delete, seeing consistent 110 braking hp on OEM dash gauge
Max Boost was down around 26 before now 30psi (small exhaust leak had started before delete)
EGTs run 1250-1350 with a heavy load running in the turbo avg 12-16psi boost. Probe right above turbo flange. No data pre delete.
Coolant and Oil temps are also down about 10 degrees consistently. Less coolant heating by EGR cooler maybe?
Passed DOT inspection at NM scale - The Ultimate Test!!! All sensors plug into stock locations - looks bone stock
Exhaust tone is slightly lower/louder than stock but would not be noticeable to most people. No to little smoke - will not draw attention to your truck.
Cons
It is hard work - that is the worse turbo location in the world! I'm sure it will be easier on the next one but what a PITA
3 days 2 guys - one day remove everything, one day gut reweld cans, clean and prep, one day to reinstall everything
Driver says his bed gets hot now ( is raised 8" above stock backseat floor-seat removed - mega cab) guess we will insulate the DPF can under the cab
Notes/Parts:
have 4-5 gallons of antifreeze on hand to replenish losses (we use Cummins brand)
Genos sells the all gaskets or local parts stores may have - we ordered complete from Genos, turbo and exhaust
Used good ol 7018 to weld up the cans - cut on welds so looks stock still. Unless you are really looking for a louder exhaust tone reusing the stock pipes saves about $500 on the project and there are no fitment issues.
Recommend having a spare turbo drain tube kit on hand or located - they are not much more robust than a dryer vent hose and could get damaged easily. Ours was fine and we kept spare for the next delete - about $120-190 at local parts store if I remember right and a week to ship.
We bought a special curved wrench to access turbo flange bolt - was not absolutely necessary but handy. I think it was $50 at snap on truck or you can order from Mopar store also. If you need the PN let me know.
We replaced the seal washers on the banjo fittings to turbo and block - got them from dodge dealer
Tuner/Programmer - will absolutely need one - we went with MM3 based on input from this forum - very happy with that decision
Tune - sky is the limit - we like the 30HP tow tune - this is a work truck and we are going to keep it until 400k. We were looking for longevity and not stressing other components ect. These trucks are mules right off the showroom floor.
Band-Aids - lots of band aids. More sharp no-see-ums and tin covers than you could imagine.
Highly recommend the MM3 and DRD tune. Spot on and easy install. Thank you DRD!
Extremely happy with the results in every aspect.
We will post oil sample results after we get a full cycle post delete and after the bypass oil filter gets installed.
Local dealer SM laughed - said he never would have known the truck was deleted just looking at it - but the ECM/tune would rat us out if they checked.
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