Build Your Own Diesel Power Wagon

Dodge Ram 2500 3500 Power Wagon Rock Climbing

When Dodge resurrected the Power Wagon name in 2005 we, like many of you, were excited about the prospects of this new off-road-ready pickup. Dodge had checked off 99 percent of the ultimate off-road boxes on the build sheet: sway bar disconnects, front and rear selectable lockers, slightly bigger tires, rock sliders, and even a front winch! Unfortunately for many, Dodge didn't mark off that one important check we all craved, a Cummins diesel engine.

Everyone knows the Cummins diesel is a torque monster of a powerplant, perfect for twisting big tires down the trail. Imagine our excitement when we realized it's now possible to build your own version of the Power Wagon out of a diesel Ram 2500 or 3500 pickup.

The Power Wagon came with a 10 1/2-inch AAM rear axle, while the diesel trucks come with a massive 11 1/2-inch AAM rear axle, and for the longest time only the factory limited slip was available. Then recently Detroit and Yukon Gear both offered a fulltime locker, but we still wanted the same select-ability that the Power Wagon offered. Luckily ARB has just released the first selectable Air Locker for the AAM rear (ARB already had the front AAM 9.25 in production) and we saw our dream diesel truck coming together.

Dodge Ram 2500 3500 Power Wagon Chevy Silverado

Power-Silverado?
The AAM 11.5 isn't just a Dodge thing. In fact, it was first offered in the back of many '01 GM trucks with the Duramax and 8.1L big-block. Since these same trucks came with the AAM 9.25 IFS front axle, you can now outfit them with both front and rear ARB air lockers as well. The IFS AAM 9.25 uses the same ARB air locker as the Dodge solid axle AAM 9.25 front axle, and the Dodge AAM front is a perfect candidate in case you want to swap in a solid axle down the road. Better yet, order up a complete Power Wagon front axle from Mopar at your local Dodge dealership with 4.56 gears, front selectable AAM locker, and speed sensors that work with the GM computer for that late-model solid axle swap. Adding a winch bumper isn't hard either, so you could very easily build a GM trail machine.

American Axle Manufacturing's 11.5 rear axle in the '03-present Dodge Cummins trucks (and '01-present GM 3/4- and 1-tons) is a massive axle designed for high-torque towing abuse. AAM's 11 1/2-inch ring gear (left) dwarfs the classic Corporate 14-bolt's 10 1/2-incher (middle) and the Ford Sterling 10 1/2-incher (right).
American Axle Manufacturing's 11.5 rear axle in the '03-present Dodge Cummins trucks (and
The AAM 11.5 still uses the 1 1/2-inch by 30-spline axleshafts similar to the Corporate 14-bolt, but the larger ring gear, massive housing, and disc brakes make it a great axle upgrade for a workhorse truck, or a diesel-powered trail machine on massive rubber. As the aftermarket grows and supplies diesel owners with higher-quality axleshafts, this Air Locker needs to be ready for any abuse sent its way, and one way ARB is preparing is by offering side gears for this locker for 35-, 37-, and 40-spline aftermarket axleshafts.
The AAM 11.5 still uses the 1 1/2-inch by 30-spline axleshafts similar to the Corporate 14
ARB's Air Locker for the AAM 11.5, the RD139 (right), is engineered to be five times as strong as the OE limited slip differential (left). This seems like a great idea considering all the cranked-up diesels out there with the 11.5 in the rear.
ARB's Air Locker for the AAM 11.5, the RD139 (right), is engineered to be five times as st

Improper installation is the Achilles heel of the ARB Air Locker, and that's why we went to the proven gear installers at One Ton Off-Road. For years we've run ARBs that One Ton has set up, with zero issues. That's important when a functioning locker is all that stands between sleeping in your truck or driving home from a muddy rocky trail. As with every Air Locker, the RD139 requires the housing be drilled and tapped for the air fitting (arrow). The copper tube seen in photo 3 runs through this fitting to the air line.
Improper installation is the Achilles heel of the ARB Air Locker, and that's why we went t
The AAM 11.5 is similar to the Corporate 14-bolt in that it uses side preload adjusters. However, unlike the 14 bolt, the AAM only uses two pinion bearings instead of three and a removable pinion support. Nonetheless the giant AAM pinion shaft (see photo number 1), the massive ring gear, and now the added selectable traction of the ARB should help these new Dodges start seeing more dirt in addition to their already proven towing ability.
The AAM 11.5 is similar to the Corporate 14-bolt in that it uses side preload adjusters. H
The air line runs to the ARB mini-compressor that pressurizes the locker. Switches inside the truck turn on the compressor, and then lock or unlock the differential. When locked, the compressor sends air to the locker, which forces a collar to slide and engage the locker so that both axleshafts are connected. This distributes power to both wheels equally, aiding traction off-road. When you return to the asphalt or solid terrain, simply flip the switch and you have an open differential for betting street handling.
The air line runs to the ARB mini-compressor that pressurizes the locker. Switches inside

The other three major factors in making a diesel Power Wagon include additional clearance for 33-inch (or taller) tires, an easy fix with the multitude of aftermarket suspension options including one from Mopar. Then there is the disconnectable front sway bar that allows greater wheel travel off road. This isn't available on the diesel Ram but can be ordered from your local Dodge dealership (PN 52121754AE). However, it retails for around $3,000 and may require custom wiring and drop brackets to clear the cooling system in a diesel. Tuff Country does offer some sway bar link upgrades for lifted trucks, and though we'd rather have the in-cab disconnect, we would suffer through some under-fender sway bar disconnects for now.
The other three major factors in making a diesel Power Wagon include additional clearance
That just leaves the front winch, another Power Wagon part that wants to reside in the same space as the diesel intercooler and radiator. For this problem we recommend looking at the multitude of aftermarket winch bumpers, such as this Fab Fours Dodge HD bumper. These aftermarket bumpers will likely take more abuse, and though they protrude farther out than a stock bumper, they also offer more approach angle directly in front of the tires.
That just leaves the front winch, another Power Wagon part that wants to reside in the sam

SOURCES
ARB 4x4 Products 720 SW 34th Street Renton WA 98057 800-761-8192 http://www.arbusa.com	One Ton Off Road N/A AK 661-317-2109 www.onetonoffroad.com
Mopar P.O. Box 21-8004 Auburn Hills MI 48321 800-992-1997 www.mopar.com	Tuff Country 4172 West 8370 South West Jordan UT 84088 800-288-2190 www.tuffcountry.com
Fab Fours 10424 Rodney St. Pineville NC 28134 866-385-1905 www.fabfours.com