FROM THE GROUND UP 

OFF-ROAD 

My RIG

SPECS

2001 Dodge Ram 1500 Quad Cab 4x4

Here is some great info from www.dodgeram.org as is most of the info on this page

Suspension

Skyjacker 5" Class II with Dual front hydro ride shocks add a leaf rear.  Will soon be changing to be adding longer custom front Radius Arms and 7 inch springs and custom 10 inch Rear Springs.

Picture from the skyjacker website, shows new springs not the add a leaf kit I have.

 

Tires 

For the Trails

 TSL Super Swampers Radials 35” x 12.5” x 16 on Eagle Alloy 589’s 16 x 10
For the Roads and winter

BFG KO’s  (315-75-R16) on Eagle Alloy 589’s 16 x 8

List of other MODS

3” Performance Accessories body lift w/ rear bumper bracket extensions
Westin Step Bars (Black powder Coated)
Warn Fender extensions (front and rear)
PUTCO Stainless steel tailgate guard
CAT back 3” Dynamax Exhaust System with Stainless tip
 K&N air filter
Vent shades
 Stainless Steel Rocker panel plating
Stainless steel grill inserts
Door seal scratch guards
Husky floor liners
Remote Auto Starter w/auto kill and LED light
High rise canonpy w/dual rear locks and 3 sliding windows and custom Bed seals and all wiring on trailer connection for ease of removal
DELTA full size RV chest Custom mounting brackets on Delta RV Chest for Pick head, Axe, D-handle shovel and, High lift jack.
Spray in box liner (Under Rail)
 Sony 50 X 4 CD player
 Pair of Sony 5 ½ three ways in the rear
Pair of Kenwood 6 x 9’s three ways in the front doors
2 x ¼ million candlepower spot lights (GROTE) All wired into the canopy on a trailer connection with separate switches for all.
2 x forward facing 55w flood lights (GROTE)
2 x rear facing 55w floods (GROTE)
2 x 55w cargo lamps (GROTE)
Reese Class 5 trailer hitch
7 pin trailer connection harrness on custom bracket
2 x rubber high volume floor mats (winter)
2 x Dodge Emblem Rubber Mats for front seats (summer)
1 rear seat floor mat
ABC fire extinguisher and mounting bracket with 5lb extinguisher
5 Gal Jerry Can Bracket with Jerry Can
4 x lock wheel nuts
 Bug deflector (does*t screw on) PCI, soon to be replace with stainless
 20 lb Fire Extinguisher bracket that holds 80 cubic foot dive tank (home made powertank)
Replaced axle breather tubes with Air Line and Steel Breather valves in the back of the truck behind RV chest and topped off with GM style axle breather tubes
Vinyl rock guard (chip guard)
Warn M12000 winch ROCKBUGGYSUPPLY.com UHTM Hawse fairlead
Custom in cab switch using ATV winch control switch
Custom inside/outside control switch
Upgraded winch hook
AMSTEEL BLUE Cable 3/8" x125'
M12000 Snatch block
Road Armor Bumper with 3” body lift extensions to full face  LINE-X spray (SOON)
Blue marker lights
2 x 3/4 steel D/rings (clevis) painted to match truck
Warn receiver tow shackle
Custom Vinyl racing stripe the runs the length of the trim line
2 in Cab marker lights (blue) mounted under dash floor
1 red clearance light mounted in dash
Midland ESP 40 Channel CB with 10 weather Channels and Dual antennas
Western Seat Covers, removable and washable
Stailless Steel Tailgate Gaurd
Hand Throttle
O2 SIMM to replace second O2 sensor
1 TON steering upgrade using 1.25 DOM and Chevy TRE's
 

 

I think that is it for now but I will leave space for more because I know there will always be more.

 

ENGINE

Engine Type
318 cid 90' V-8 OHV 
Bore & Stroke
3.91 x 3.31 in..(99.3 x 84.0 mm) 
Displacement
318 cu.in. (5.2 L) 
Compression Ratio 
9.1 :1 
Horsepower
230 hp @4400 rpm
Torque 
300 ft. lbs. (407 N.m) @ 3200 rpm 
Firing Order
1-8-4-3-6-5-7-2 
Lubrication
Pressure Feed - Full Flow Filtration
Engine Oil Capacity 
5.0 Qts. (4.7 L) with Filter 
Cooling System
Liquid Cooled - Forced Circulation 
Cooling Capacity
17.0 Qts. (16.1 L) 
Cylinder Block
Cast Iron 
Cylinder Head
Cast Iron 
Combustion Cambers 
Wedge - High Swirl Valve Shrouding 
Camshaft
Nodular Cast Iron 
Throttle Body Bore 50 mm
Pistons
Aluminum Alloy with Strut 

Transmission

5 Speed NV3500 is a medium duty, 5-speed, constant mesh, fully synchronized manual transmission
  • Manufactured by New Venture Gear
  • Order code: DDC
  • Input torque rating: 300 ft-lb
  • Max GVWR: 7,200 lb
  • Max GCVWR: 11,000 lb
  • Fluid Capacity: 4.8 pints to the bottom of the fill plug 
  • Weight (with oil): 110 lb
  • Mopar Manual Transmission Lubricant (PN 4761525) is the ONLY lubricant recommended for the NV3500.
  • Fill Plug: Front housing on passenger side
  • Drain Plug: Bottom of the front housing
     The transmission gear case consists of two aluminum housings. The clutch housing is not a removable component. It is an integral part of the transmission front housing.
       A combination of roller and ball bearings are used to support the transmission shafts in the two housings. The transmission gears all rotate on caged type needle bearings. A roller bearing is used between the input and output shafts.
       The NV3500 has a single shaft shift mechanism with all three shift forks mounted on the shaft. The shaft is supported in the front and rear housings by bushings and one linear ball bearing. Internal components consist of the forks, shaft, shift lever socket, and detent components.
      The transmission is disassembled and serviced by unbolting and splitting the case into a front half and a back half.
Clutch Disc Diameter

11", 281mm

 
Gear Ratio
1st 4.01
2nd
2.32
3rd 1.40
4th 1.00
5th 0.73
R
3.55

TRANSFER CASE

NV231HD
Weight
(lb)		 72
Input Torque
(Cont ft-lb)		 730
Input Torque
(Max ft-lb)		 1,940
GVWR
(lb)		 6,400
Fluid Cap
(pt)		 2.5
Ratios:
L = 2.72

H = 1.00
The NV231HD,  features larger bearings and a wider chain than the NV231. All versions of the 231 cases use three gears in the planetary reduction set.

Transfer case operating ranges are selected with a floor-mounted shift lever. The shift lever is connected to the transfer case range lever by an adjustable linkage rod. A straight line shift pattern is used.  The 231 is a  part time transfer cases with a low-range gear system and three operating ranges plus a Neutral position.

On the NV transfer case, the gear cases, retainer, and extension are all of aluminum. Drive sprockets and an interconnecting chain are used to transmit engine torque to the front and rear propeller shafts. The mainshaft, input gear, and front output shaft are supported by ball and needle bearings.

A synchro mechanism consists of a brass stop ring, synchro hub with three struts and two retaining springs, and the sliding clutch. The synchro components allow the transfer case to be shifted between 2H and 4H ranges while the vehicle is in motion. However the vehicle must be stopped or moving very slowly to shift into 4L range

Here is some great info from www.dodgeram.org as is all the info on this page. Transfer Case Identification Guide (pdf)

FRONT Axle

  CURRENTLY SOON TO BE
Dana 44 (216) Dana 60 (248FBI)
Axle Type
.......................Hypoid
..................................Hypoid
Axle Tube Thickness
0..39"
0.50"
Lubricant Specified
Thermal Stable SAE 80W-90 GL5 
Thermal Stable SAE 80W-90 GL5 
Lube Capacity
4.8 pints ( 2.28 L )
7.8 pts. (3.6 L )
Axle Ratio Options
3.54
4.56
Ring Gear
Diameter 
Backlash 
 
8.50 in. ( 215.9 mm ) 
0.004- 0.009 in. (0.10-0.23mm) 
 
9.75 in. ( 247.7 mm ) 
0.004- 0.009 in. (0.10-0.23mm) 
Axle Shafts
30 Spline, 1.31" diameter (inner)
1.34" (outer)
30 Spline, 1.31" diameter (inner)
1.34" (outer) (a)
Axle spline pitch 1.25" 1.5"
Axle Shaft material
Low carbon Alloy
Low carbon Alloy
Crossjoints  
Chrysler 7290, 1.125" Cup, 2.625" Cross
Pinion mount Overhung Overhung
Pinion shaft diameter 1.376" at inner bearing
1.35" at outer bearing		 1.63" at inner bearing
1.25" at outer bearing
Pinion Standard Setting 
4.312 in. ( 109.5 mm ) 
5.000 in. ( 127.0 mm ) 
Pinion Bearing Preload  
Original Bearing

New Bearing

10- 20 in. lbs. ( 1-2 N.m )

 10- 20 in. lbs. ( 1- 3 N.m )
20- 40 in. lbs ( 2.3-4.5 N.m) 20- 40 in. lbs ( 2.3 - 5 N.m )
Axle breather tubes made using 1/4 inch self coiling air line that ends behind the tool box

REAR AXLE

Corporate 9.25" Rear Axle
Axle Type
Semi-floating, hypoid 
Lubricant 
API GL 5, SAE 75W-90
Lube Capacity
4.9 pints ( 2.32 L ) 
Axle Ratio Options
3.21, 3.55, 3.92 

Carrier Split

 none
Differential 
Case Clearance 
Case Flange Runout 
Bearing Preload 
0.005 in. ( 0.12 mm ) 
0.003 in. ( 0.076 mm )
75 ft. lbs. ( 102 N.m ) 
Ring Gear 
Diameter 
Backlash 
Runout 
 9.25 in. ( 23.50 cm)
0.005-0.008in. (.012-0.20mm)
0.005 in. ( 0.127 mm)
 Pinion Bearing Preload 
Original
New 
  10-20 in. lbs. ( 1-2 N*m)

15-35 in. lbs ( 2-5 N*m)

Axle breather tubes made using 1/4 inch self coiling air line that ends behind the tool box

9 1/4" Axle Parts List (see parts diagram for identification) Provided by www.dodgeram.com

 

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