Can my old PSD take some more power?

[SeEKandDESTROY2]

I have a 1996 F350 PSD with 242k on the clock. It have the DIY straight pipe and a DIY intake coming this week. I've broke a transfer adapter a while back when the previous owner had a Mechanic do U-joints from the T-case back, and he didn't loctite the driveshaft bolts to the Output shaft. 2 vibrated loose and caused the adapter to fail.

Anyways, am I safe to throw a tuner on, maybe do some turbo work? What do you guys reccomend to get the best power out of my budget. Btw what axles are underneath my truck? Thanks, Pete

[Power Hungry]

The thing with the OBS is that you're going to be limited on power anyway because of the smaller injectors, so the chance that you'll break something is significantly lower than if you had a Super Duty. In most cases, about 65 to 70 HP increase is the best you can expect.

Tony Wildman at TDP does a lot of work on OBS trucks and is very well respected. He was even in this month's Diesel Power magazine chip shootout. We can also provide you with tuning if you're interested.

Can't help you on the axles, though.

Take care.

[Dieselfever78]

Dana 60 front and sterling 10.25 in the rear. Either 4.10 or 3.55 gears

-Michael

[kylev90]

the biggest thing you are going to have to worry about with adding power is the tranny. But if your looking to just do intake exhaust and tuning you will be fine.

[ryandamo]

you can get alot of power with just a chip, tuner and exhaust, get an exhaust gas temp gauge tho

[Adam-Arc]

Do the full set of gauges on the a-pillar to be safe.

[kanuck15]

i started doing mods at 247k and havent had an issue yet with mine, just simple stuff like intake, exhaust, TS chip, but certainly get yourself some gauges, What transmission do you have?
Odds are being a 350 you have a dana 60 up front and a sterling 10.25 in the rear. Ive beaten on them for years and they take it very well

[Tsgs69400]

My, friend has 420,000 on his 96 5 spd and has stg 1s and tuner and intake. His weakest link has been the rear diff yoke. He has broke 2 of them.
I think that the stock autos are the weakest link with all things considered.

[kanuck15]

yeah on my 96 with a 460 gasser ive broken 3 or 4 yokes...granted rolling off 37 inch super swampers on dry pavement didnt help me not brake them lol. but your right the e4od trans is a weak point, also on the 94 and 95 models the borg warner 1356 transfer cases are weak. between mine and my dads truck we have eaten alot of them (his being a 94 and mine a 95) yet my 96 has a borg warner 4407 that ive beaten on and its a better unit, hence why ford upgraded to it

[7.3toyhauler]

you will be fine i have inj, chip, intake, exhaust and gauges with 264k miles with no problems yet