* Specific Turbocharger Model: The 2004 Dodge 2500 Cummins came with different turbocharger models (e.g., HE351, Holset HX35), each having different capabilities and limitations.
* Modifications: If the truck has any engine modifications (upgraded injectors, fuel pump, aftermarket tuning, etc.), the safe boost pressure will be significantly affected. Modifications can drastically increase the potential for damage at higher boost pressures.
* Condition of the Engine: A well-maintained engine can handle higher boost pressures than a worn-out one.
* Altitude: Higher altitudes reduce air density, affecting boost pressure.
Without knowing the specifics of the turbocharger and any modifications, it's impossible to give a safe maximum boost pressure. Exceeding the safe boost pressure can lead to catastrophic engine failure, including:
* Rod Knock: Connecting rods failing due to excessive stress.
* Head Gasket Failure: Head gasket blowing due to high cylinder pressure.
* Turbocharger Failure: Turbocharger seizing or blowing.
Recommendation: To determine a safe boost pressure for your specific truck, consult a qualified diesel mechanic or refer to the specifications of your particular turbocharger and any modifications that have been done to your engine. Using a boost gauge is highly recommended to monitor boost levels. Many owners aim for a safe and reliable boost range, and exceeding this without proper modifications and tuning is very risky.
