Mopar1973Man

You on the right path take care of the weak points first then add your power accordingly.

I've got ask why not just replace the entire dash top? LMC Truck sells the dash top.

235 HP at the flywheel isn't much power. Like I'm also running 7 x 0.0085 injectors, Quadzilla Adrenaline pulls like a dream. Bad combo really. The 100 HP injectors need better control of fueling and timing than what the Edge EZ can do. Remember canned tuner like the Edge EZ are designed for stock only injectors. The timing needs to be advanced more for larger injectors and fuel curve needs a bit of lag time to allow for boost building. This where the Quadzilla shines over the other tuners.

You do not have the means to repair an common rail injector. You'll need to send that injector in as a core and just replace it. WARNING: If you do try to use a shade tree repaired injector you take the risk of melting down that piston. I highly suggest that injectors are replaced as a full set and not just one.

Roughly 5 to 10 bar drop. 1 bar is 14.5 PSI.

This is why I suggest NOT buying a Cummins thermostat being it is exactly the same as a NAPA except the price is MUCH lower on the NAPA. I can't see paying the big money on a Cummins when it no different than the NAPA same design just way cheaper. https://www.genosgarage.com/product/gates-thermostat-34212/thermostat This is what I'm running now and it sucks. Wild up and down swings in temperature.

So far the two NAPA's have worked perfectly. The 180*F ran at about 186 to 188*F rather solid and never moved. The NAPA 190*F ran like 195 to 197*F pretty solid and not moving. Now the Gates that crazy thing is up and down constantly like an old 12V 180*F thermostat. Like I said the return home is a bit better but still cycling. The Gates looks just like a NAPA in design the same large mouth design. Now the Cummins on the left looks like the old school NAPA thermostats that are no longer sold. Small mouth and brass bypass plug. Both NAPA... You'll see that the old school NAPA thermostat looks exactly like a Cummins. The upgraded NAPA has a much wider mouth. Old on the left and new on the right... Again old on the left and new on the right.

While you at this point make sure to replace or lube the pedal pivots.

Like my little 1996 Dodge Ram 1500 is starting to do this too and mine is simple it just the moisture creating rust in the drums. The first couple of taps on the brakes its locking up just barely touching the brakes. As for @The_Hammer I would say double check that ABS light see if it is truly on. Might be fighting another issue with the ABS system. If you do have the load valve in the back disconnect the arm and tie it in the up position. (IIRC).

Might read these and see if they help out.

Possible...

The only thing I can think of is finding the fog light ground and make sure it clean. It shows "exterior light system" for ground. I'm going to assume the ground at the front fender driver side near the headlight possibly.

I might give this a chance yet. My trip home the swings start getting shorter back and forth. Still swinging down to 192*F and back up to 208*F back and forth.

Having your injectors popped below 310 bar is a waste. So far everyone that has had re-popped injectors all showed a fairly good drop in pop pressure. @Dodgeih being the biggest drop.

I might just buy a 200 amp breaker fro the driver side battery and hook up the grid heater to the breaker. Then in the summer just push the button and let it open the circuit. Then in the winter close the breaker. Still, code free method. @IBMobile is more of in-cab control that doesn't trip the codes. California smog...

I can tell you Gates thermostats are junk. The 200*F thermostat I got has 30* swing from cold to hot. Heats up to 208*F pops open and drops to 188*F and starts over. Hottest I seen was pulling a 6% grade at 212*F. Then the coldest is pulling in to a parking lot idling at 175*F with an outside temperature of -4*F. Really? Never settles down at all. I'll be pulling this out and dumping it. Notice to others just because its name brand thermostat doesn't mean its good. Gates is a fail in my book. At least the NAPA thermostat are very stable and don't cycle like this. Typically the 190*F floats right at 195* to 197*F stable.

Use a mirror and a small flat blade screwdriver bent an L shape to hook the copper shims. There has to be something in the base of the hole if the injector isn't seating completely.

Remember some places like Idaho in general is not a smog state. But... Ada county and Canyon county is smog areas and are based on exactly what @IBMobile said. Ive spent enough time talking to one guy at a smog station in Boise.

Remember, that's injectors and a tuner. Take notice to timing.

Same here... I'll keep the heap...

Minus 50*F off that for correct EGT's as shown by my ISSPro. The Quad is +50*F higher.

Should reduce the EGT's some.

Sway bar... Not track bar. Vacuum pump did you install the shaft seal the right way? If you reverse the seal it will leak.

First I got to ask is the rubber all oily and greasy? Is the rubber soft and mushy holding the sway bar? If any of these are true then the bar might slide back and forth no matter how much you torque the fasteners. You might be forced to replace the rubber sway bar holders. At the same time fix the source of the oil leak. Engine oil is great at making rubber stuff mushy over time.

After the Cummins got the cold shoulder and the cold garage for 17 days I'm sure it's going to straighten up and act right. If not the little Red 1/2 ton will steal its glory again.