Diesel Fuel Economy Increasing Diesel Fuel Mileage

I drive a 2006 Dodge Ram, 5.9L, Cummins, 2500, 4x4, 4-speed auto, 3.73 rear-end. I try to run at least B20 in every tank. I’m currently averaging 24-25 mpg running 70 mph with the Workhorse module. Without the Workhorse module and running the factory settings, I receive about 23 mpg. The wind factor has a tremendous impact on fuel economy on a truck of this size. I’m running the fuel efficient Amsoil HDD 5W30 engine oil with the Amsoil by-pass system. I have the Diesel Power PSM air intake hose with a drop in Amsoil air filter and the Diesel Power Cool Hose. I swapped the factory restricted muffler for the free flowing Areoturbine muffler. Other fluid replacements include Amsoil ATF in the transmission, transfer case, and power steering. I also run Amsoil gear lube in the front and rear differentials. I have a MAG-HYTEC transmission pan to help keep the transmission cool and allows for easier fluid changes. My future upgrades include a CFM+, MAG-HYTEC rear differential cover, F.A.S.S. fuel system, intercooler, transfer tank, and gauges that include a common rail pressure gauge.
I buy everything I can through Diesel Power Products. Bryan treats me more like a friend than a customer. He has spent lots of time on numerous phone calls helping me make good product decisions. His wide selection and product availability makes it easy to make Diesel Power Products a one-stop-shop. Hands down, this is the best place for excellent customer service.

Diesel Enthusiast
2006 Dodge Cummins
2005 Jeep Liberty CRD

Here's a link to a thread on the Turbo Diesel Register with a similar topic: http://www.turbodieselregister.com/forums/3rd-generation-ram-forum-no-engine-transmission-discussions/201718-psm-dpp-cool-hose-smarty-jr-fuel-economy.html

Below is just a sampling of our favorite fuel economy items for 04.5-07 5.9L Dodge Cummins. Please visit our ONLINE STORE to find similar items for your diesel truck. Feel free to call us we'll be glad to point you in the right direction to help you increase your diesel's fuel economy.

03-07 5.9L Dodge Cummins Smarty Jr.	$495
This is THE best programmer on the market for the 03-07 5.9L Cummins. It has proven to offer the best combination of mileage and power available. No other programmer can touch it for throttle response, period. If you need more options and adjustability the original Smarty is what you are after. If you strictly want increased diesel fuel ecomony pick the Smarty Jr. FREE 2nd Day SHIPPING! Fast guide to Smarty-JR Features CaTCHER software's inside Three different performance levels: 40 / 70 / 100 hp Improved fuel economy Optimized drivability Fastest download in the industry, up to three times faster than the competition, a typical ECM update takes about 3.5 to 5 minutes, depending on the truck model ABS tire height updates in just few seconds from 22,5" to 44" Not traceable in the stock setting. Smarty leaves no footprint Cold weather 3 Cylinder High Idle is enabled in all softwares Reads Diagnostic Trouble Codes in plain text No tools required, no fuses to pull USB built in for simple updates from internet Easy installation Reliable, it works off your OEM hardware Fast guide to Smarty-JR software levels The horsepower settings have a modified "Torque management" ( TQM ). The throttle response is greatly improved but is set to a save limit. With "Save" I mean save for your tranny and rest of the driveline. SW # 1 : 40 Hp increase SW # 2 : 70 Hp increase SW # 3 : 100 Hp increase Tested on stock trucks on a Dyno. Stock means just that. Stock! Even the air filters were stock... The trucks were S T O C K, even the wastegate settings! We checked the "baseline" ( the stock truck Hp at the rear wheels ) twice in a day in order to be sure about our findings. The above declared HP numbers are all rounded down to the closest number. No trace is left in the ECM! I herby CLAIM that SmartyCR is the FIRST AND ONLY downloader that does not erase any of the stored data in the ECM. Smarty does NOT leave any electronic footprints in the ECM or any other electronic module in the truck. Smarty does NOT set ANY codes once the ECM is set back to stock. Smarty does NOT need to have fuses pulled. No matter what the competition claims , in one way or another they're ALL detectable. Smarty is NOT! Yet, Smarty can not do one thing for you. Fix what others have broken. Smarty can not restore a key on counter that another downloader has erased . Smarty can not fix VIN# troubles caused by other products. If your Check engine / ABS light is on because another product has screwed your ECM, Smarty can not fix it, the other guy HAS to... ABS / Speedo recalibration The tire height can be adjusted up to 44" in increments of 10 tenth of an inch in just a couple seconds. Of course, Smarty needs to be VIN# locked to the truck in order to get into the ABS adjustment section. DTC Code reader The name says it all. You can read and erase codes. Codes are displayed also in plain English. That's old news by now. Smarty S-03 was the first one to provide that utility, others found the idea to be a good one too. ( Smarty does erase ABS codes too but does not display them ) ECM update speed Faster than anything else on the market! Again we've done our homework on the protocol. Less than 5 minutes. Three times faster than a Star-Scan diagnostic tool or competitor. We have developed our own bootloader in order to not have to pull fuses should an update become interrupted for any reason. All you have to do is to turn the key off / key on Smarty does everything else on it's own. Updates The CaTCHER softwares as they are today are only a starting point. Expect major news in future. We’re for your feedback, opinions, likes, dislikes... [ More Information ]

CFM Intake 03-07 5.9L Dodge Cummins - No ports	$varies
This is the version with no drilled and tapped ports. It does have a boss that you can drill and tap. The version with 3 drilled and tapped ports is also available on ths page. Why is the CFM+ the ultimate intake manifold? Regardless of which tuner, air filter, exhaust system or aftermarket intake you may already have, you need to dramatically increase your air flow. No other aftermarket intake comes close. Even without a computer it’s easy to see why the CFM+ (CFM Plus) flows so much better than the angular stock aluminum manifold with its nearly 40% flow restriction at the front mounting bolts. But why does the CFM+ (CFM Plus) flow so much more air than the other oversized cast aluminum manifolds in the market and maintain lower air temps? There are a number of reasons: 1.) The very large center section of the competitor cast aluminum manifold may look impressive but it is very bad for flow. The inlet to the manifold from the inter cooler and the outlet of the intake manifold into the engine are very similar in cross-sectional area so when the center section is over three times larger than the inlet and outlet the air flow slows dramatically through this center section. The air flow then is forced to speed up to exit. This causes turbulence in the flow, leading to pressure drop or pumping losses. 2.) The competitor’s manifold is so oversized in the center section that two of the mounting fasteners which hold the intake to the engine had to be changed to long bolts or studs that must pass directly through the air flow. This causes tremendous turbulence in the flow leading to additional pressure drop or pumping losses. 3.) You can also see in the picture of the cross-section of the competitor aluminum manifold there are two surfaces (Fig.2) protruding down into the flow path that create recesses into the outside surface of the manifold. These pockets allow the mounting nuts to look good recessed on the outside but cause a big problem on the inside where it matters. These two surfaces protruding into the air flow act to trip up or tumble the air flow. Again this causes additional turbulence in the flow leading to pressure drop or pumping losses. 4.) Cast aluminum has a much rougher surface than the advanced technology composite CFM+ manifold. The rough interior surface of the competitor’s cast aluminum manifold causes additional turbulence. It should now be evident why there is a 44% increase in air flow over stock and a 20% increase over the cast aluminum manifold of the competitor. These tests were performed on a SuperFlow model SF-1020 Probench. Changing to the CFM+ over the competitors cast aluminum aftermarket manifold gives almost the exact benefit as replacing your heater grid with a free flow spacer. 5.) The volume of air that can get stuffed into the engine is also greatly affected by the density of the air flow. This is why the material the manifold is made of is so important. If the manifold’s material acts to insulate the hot under the hood air from reheating the air flow that has just come out of the inter-cooler that is a very good thing for maintaining air density but if the material readily conducts heat such as aluminum that would be bad since the hot under hood temps would raise the air entering the engine since under the hood temps are by definition higher than ambient or outside air temps and heat flow is always from high to low temp. A materials ability to allow heat to pass through it is called its Thermal Conductivity represent by k in engineering equations. Aluminum has a Thermal Conductivity rate or “k” of 236 W/M- °K. The CFM+ composite material’s Thermal Conductivity rate is, 0.25 W/M-°K , which is 944 times lower. Also the oversized cast aluminum intakes present more aluminum surface area that absorbs more under the hood heat and transfers it into the air flow. CFM+'s advanced engineered composite material is high strength and durable. CFM+ (CFM Plus) is the ultimate intake for the Cummins Diesel. Available with one port ready to drill and tap or with 3 ports already drilled & tapped. [ More Information ]

DDP 04.5-07 Dodge Cummins Economizer Nozzles	$749
No other upgrade on a Dodge Common Rail can provide the stump pulling torque that a set of Dynomite Diesel injector nozzles can. Some of the electronic boxes available today can actually crack your injectors, causing thousands of dollars in repair bills. Be confident that you have a mechanical change that will add reliable power, without the headaches. If reduced smoke, more power, and better mileage are what you are after, then you have come to the right place. -------------------------------------------------------------------------------- These nozzles are desinged to give you a fuel mileage increase. Along with your mileage increase, you will gain about 25 horsepower. -------------------------------------------------------------------------------- Included with your nozzles is a nozzle removal tool to help you change the nozzles. This tool gets clamped in a vise and holds the injector so you can easily remove the nozzle. Also included in the box are color instrutions, a set of copper washers, and a core return form. Please return the nozzle removal tool with your core nozzles for a full refund. -------------------------------------------------------------------------------- As always, this product is covered by our 3 year unlimited mileage warranty and our 30 day money back guarantee. [ More Information ]

FASS 95 Series 94-07 5.9L Dodge Cummins	$607.05
Please specify your trucks year, 4x4 or 4x2, longbed or shortbed at checkout so we can ensure that you get the right kit. Complete Kits: All FASS Fuel Air Separator Systems and the High Performance Fuel Pump systems are complete kits. They come with the hoses, fittings, mounting hardware, etc to do the job. Everything needed to complete the install should be included, except tools and wire ties. FASS Configurations: FASS 95 Series is a new, smaller, more compact system with new, smaller filters. Filter life is about 1/3 to 1/2 that of the 150 Series filters. FASS 150 Series is the same FASS system that we have been selling for quite some time. Uses the same filters as before. HPFP ( high performance fuel pumps ) are available for those wanting a reliable fuel system without the added filtering. FASS Flow Rates: 95gph is for stock to 600HP applications. This is the kit for most people. 150gph is for 600HP to 700HP applications. 200gph is for 700HP+ applications only. Note: You do not want to run a pump with a higher gal per hour rating than your engines hp or the life of the FASS fuel pump will be greatly reduced. Pump noise is greatly enhanced with the larger flowing pumps. FASS Part Numbers: FASS Model Number / Flow Rate - Application Number. Typical application could include: FASS 95/95-0000 means 95 series FASS system, 95gph flow rate FASS 95/150-0000 means 95 series FASS system, 150gph flow rate FASS 95/200-0000 means 95 series FASS system, 200gph flow rate FASS 150/95-0000 means 150 series FASS system, 95gph flow rate FASS 150/150-0000 means 150 series FASS system, 150gph flow rate FASS 150/200-0000 means 150 series FASS system, 200gph flow rate HPFP-95-0000 means stand-alone fuel pump, 95gph flow rate HPFP-150-0000 means stand-alone fuel pump, 150gph flow rate HPFP-200-0000 means stand-alone fuel pump, 200gph flow rate FASS Fuel Air Separator Systems Eliminate Power-Robbing Air From Diesel Fuel: Consistent Engine Performance Increased Horsepower Increased Fuel Economy Reduces the effects of "Hot Fuel" Easier/Quicker Starts Reduced Engine/Cab Noise Improved All-Weather Performance Reduces Black Smoke Reductions in NOX and Carbon Monoxide Excellent Cold Weather Performance Smoother Idle and Quicker Throttle Response Extended Fuel Filter Life Features: Fuel Pump 10-Micron Filtration Water Separator Includes Fuel Heater [ More Information ]