How to improve fuel efficiency
 

I have a 2007 Dodge Mega Cab, 2500 Cummins 5.9L daily driver truck that I am looking to upgrade.
My goal is focused on improving fuel efficiency while remaining quiet; not horsepower or speed (I haul rarely). Albeit, each will likely improve as the engine's efficiency is upgraded. Currently, my stock truck is at 19 mpg, I want 35 mpg.
Overall for upgrades, I want my engine to breathe better- more cold dense air in, and less restrictive manner to get the exhaust out.
The four Banks items I am looking to upgrade with are:
1/2- Banks Ram-Air Intake System with Banks Super-Scoop Kit,
3- Banks Techni-Cooler System package (but with the 3 ½” mandrel bent boost tubes from the ‘42766-monster-ram-intake-w-boost-tube-2003-07-dodge-5-9L’ package), and
4- Banks Big Hoss Intake Manifold System.

Four non-Banks items I'm drawn to for upgrades as part of my plan are:
1- BD Ported Wastegate T6 exhaust manifold,
2- Turbo Smart Hyper-gate 45mm,
2- MBRP 5" Quite Tone muffler exhaust system, and
4- Wicked Wheel 2 or another turbine wheel upgrade to pull in more cold air

Is the package I am putting together on track to improve fuel efficiency?
What advice can you offer to help me reach my goal for increased fuel efficiency?
Do any of the Banks or other products I am planning to partner together not work well together?
Does the Super-Scoop Kit ever lead to water intrusion into the intake? If so, are there cheater tips to prevent this?
For programmers, is the Bully Dog GT good for what I am working to accomplish? I had one given to me. So no skin in this model if it isn't what I need.

Thank you for your time.

Jay

I don't think you will ever get 35 MPG. That being said, I would go with a smarty JR on top of what you list. Be sure to experiment and report back on what you end up getting MPG wise. Are you a manual or auto trans? My 05 3500 dually gets 18.5 with an auto but I have mods. 3.73 or 4.10?

I appreciate your insights on the Smarty JR. My truck has a 3.73 auto trans.
Any thoughts on Banks Power for the air intake and super-scoop versus S&B for the same items?
Thank you for your time.

35 mpg lol maybe going down wind and down hill with no throttle! No offense but If you don't want HP for fun or need a work horse buy a TDI or something for a 35mpg diesel. The mods you mention will help but honestly your stock box is fine, just put a BHAF on there unless you want more turbo noise or cool look when you pop the hood. The intercooler and intake manifold you will gain more HP/tq and drop temps. Leave the stock intake horn unless you want to dress it up. If you are all highway miles Look into 35s. I gained 1-2 mpg with 35s but I have 4:10. If you wanna go all out get a tight tq- less trans slip = more mpg. I think maybe you can get 23-25mpg with upgrades and driving 60mph everywhere/an extremely light foot. Let us know your results!:pca1:

You are getting about as good as mileage as you're gonna get. All of those things you listed will be a waste of money and not improve mileage. Stock trucks get the best mileage. You can put manual locking hubs and gain a tiny bit more mileage. Keep your IAT's up, like 100* + and put a 200* thermostat to gain a little mileage. I think you said you have a 2007, so EFI live will be your best option for tuning.

I second the EFI I ment to mention that! No other box tuner compares!

I appreciate your insights on the BHAF, tranny upgrade, and 35s. I'm learning there are not many upgrades tied to fuel efficiency, but boatloads tied to hp+ and tq+. Thanks

Thanks for your feedback on items that'll bring me closer to my goals. I'm learning a lot- and have some more homework.

35 mpg is being waaaaaay optimistic. Propane injection will also help, BUT, you will never reach 35 mpg unless youre going steeply down hill with a hurricane pushing you from behind.....maybe. BUT, Ya never know, you might be the first to make that breakthrough.

UPDATES: I've crossed a few items off my list for efficiency mods based on Great feedback and More research. And added a few new ones. I listen and want your feedback.
My goal remains focused on improving fuel efficiency while remaining quiet; I'm not after horsepower or speed. Currently, my stock truck is at 19 mpg, I wantED 35 mpg, but have re-scaled my expectations from your feedback to aim at 25 mpg.

New items I am looking at for upgrades:
-- HE351 Turbo mods to compressor and turbine- Turbo Resources has been recommended to me and I am in touch with Austin/Ian. Looking at 'Holset HE351CW Turbine Housing + Shaft Upgrade 67 mm'. Let me know if this is on target or needs adjustment to another Turbo mod (model/maker/sizing/?)
-- Do you think Turbo Resources' 'HE351 HX40 67mm Billet Compressor Wheel Upgrade' (on top of the aforementioned) will increase or decrease fuel efficiency?
-- Cams are an item identified to me as a hard part mod for efficiency- Hamilton 180/220 is on my radar for a daily driver (but my research is in its ground-level stages and open to guidance on manufactures/models/sizing).
-- I'm looking for tips to keep my IAT up (100*) and a thermostat to stay under 200*
Which makes/models have been successful for your trucks?
-- Tuners- Smarty Jr., EFI live, Smarty UDC Pro, and Diablo Sport Extreme or Predator programmers: which programmer is best for fuel efficiency?

Items on my original update list with adjustments or changes in priority:
-- MBRP 5" Turbo back exhaust system (possibly with Quiet Tone muffler as I like quiet) - still looks good to decrease exhaust backpressure
-- Cold Air Intake- Banks Ram-Air Intake System with Banks Super-Scoop Kit; or S&B's equivalent; or just a BHAF by AFE.
-- Banks Techni-Cooler System package (but with the 3 ½” mandrel bent boost tubes from the ‘42766-monster-ram-intake-w-boost-tube-2003-07-dodge-5-9L’ package), and
-- Banks Big Hoss Intake Manifold System- is this intake manifold system necessary if I'm looking at an intake horn upgrade? Which one gets the most efficiency out of the 5.9L Cummins?

Items I've crossed off my original list are: (and let me know if they should be placed back on the 'do' list)
1- BD Ported Wastegate T6 exhaust manifold: not necessary as enlarged manifold does not create the pressure necessary to maximize / power the turbos
2- Turbo Smart Hyper-gate 45mm: not necessary as I'm not looking combining enough turbos to overpreassure the exhaust manifold
3- Wicked Wheel 2 or another turbine wheel upgrade to pull in more cold air: I'm on the fence here as turbine wheel upgrades bring more air into the turbo for efficiency but are usually intended to increase horsepower (I'm considering Turbo Resources).

Achievements:
600 lbs of sandbags placed at the tail end of the truck bed gave me 2mpg. My theory is the added weight over the rear axle transforms the rwhp into moving Big Blue forward instead of spinning the tires. My attention focused here because within 5K miles of buying the truck my rear tires were noticeably worn. I'm looking to place a 1/2" steel plate back there to cut down on the space required for 12 sandbags.

Thank you for your time and insights.
Jay