Cost-Effective Modifications - 2008 Dodge Durango

2008 Dodge Durango Modifications True Flow Air Intake System

01. True Flow has a high flow air intake system for the 4.7L V8 Durango that significantly outflows the factory piece while still retaining the Dodge’s original air box.

01. True Flow has a high flow air intake system for the 4.7L V8 Durango that significantly

As some of you are well aware, we awarded the 2008 Dodge Durango our coveted SUV of the Year award at the time of testing. One of the issues with the long term test vehicles provided us by the manufacturers is the inability to do any modifications to said vehicle. We managed to run down a healthy and clean used example allowing us to show you what can be done with one of these fun and versatile SUVs. Our unit is a 2WD with a PowerTech 4.7L V-8 under the bonnet, factory rated at 235hp and 300 lb-ft of torque. However, those numbers are at the crank, so we will be running the Durango on the dyno to see how our before and after figures come out at the wheels.

With an open book to do whatever we pleased, we brainstormed a ton of ideas and ran down plenty of scenarios. After the dust settled, the decision was made to bring this mid-size performer up to a respectable and streetable trim without going overboard. What could be done by most owners with minimal effort and still be easy on the wallet should you be completely unable to do any of the labor yourself? With K.I.S.S. (Keep It Simple Stupid) running through our collective brains, we sought help from the pros. True Flow was sourced for one its high-flow intake conversions and Gibson exhaust pulled an aluminized exhaust from its inventory. On the outside, we contacted E&G Classics for a stainless mesh grille to replace the stocker and Tom McWeeney of Kustoms Inc. used paint from PPG to color the door handles and rear hatch trim for a matching fashion statement. Wheels and tires were also included in our makeover, so we went to the local internet ads for a used set. Follow along as we dress up the Durango with more sense than cents.

2008 Dodge Durango Modifications Factory Induction System

02. This is the induction system as it comes off the factory assembly line. It has plenty of sound-deadening chambers to slow the air from getting where it wants to be. After uncoupling the Inlet Air Temperature (IAT) sensor, it was a snap to remove.

02. This is the induction system as it comes off the factory assembly line. It has plenty

Time Frame: One day, with the exception of the Kustoms Inc. paint which took two days.

Degree Of Difficulty: Easy to Moderate

Tools Needed: 9/16”, ½” and 13mm wrenches, hand-held drill, Phillips screwdriver, 13/16” socket and torque wrench, floor jack and HVLP paint gun.

Parts Used:
E&G Classics 1103-1102-07 grille … $221.25
True Flow 30505 intake … $295.26
Gibson 316593 exhaust … $530.18
Boss Motorsports 304 wheel … $300.00 (each)
Nitto 285/45R22 NT420S tire … $260.00 (each)
Painted handles and trim … labor rates vary

03. We began the install by dropping the new washable, two-part foam filter into the factory lower air box.
03. We began the install by dropping the new washable, two-part foam filter into the facto
04. Once the IAT sensor was removed from the stock intake tube, it was slipped into its new home.
04. Once the IAT sensor was removed from the stock intake tube, it was slipped into its ne
05. All the supplied silicone couplers were loosely fit into their respective positions and the True Flow tube was fit to the PowerTech motor’s throttle body.
05. All the supplied silicone couplers were loosely fit into their respective positions an

06. With the factory air box lid slipped into position, a couple turns of our nut driver had all the connections tightened and sealed.
06. With the factory air box lid slipped into position, a couple turns of our nut driver h
07. Lastly, the IAT electrical connector was clipped back to its home, leaving us ready to start the engine.
07. Lastly, the IAT electrical connector was clipped back to its home, leaving us ready to
08. Twisting the key fired up the engine and we checked the True Flow system for any air leaks or the dreaded Check Engine light. You can clearly see how the True Flow intake straightens the air path and aims it directly at the throttle body.
08. Twisting the key fired up the engine and we checked the True Flow system for any air l

09. On the ground, Shawn Seidelman of Gibson, had laid out the exhaust portion of our chosen performance enhancements. Less pieces means easier installation.
09. On the ground, Shawn Seidelman of Gibson, had laid out the exhaust portion of our chos
10. It’s boring to see a rusty, stock exhaust so we skipped to the good part. The Gibson versus factory muffler is not only a weight savings but also a longevity investment. The original exhaust on our Durango was a rusted mess despite only being two years old.
10. It’s boring to see a rusty, stock exhaust so we skipped to the good part. The Gibson v
11. Shawn started by slipping the head pipe in place and reattaching the ground strap using the original hardware. Details like this separate the amateurs from the pros.
11. Shawn started by slipping the head pipe in place and reattaching the ground strap usin

12. Next was the Superflow muffler. This piece will provide excellent flow without making too much noise—exactly what you need for a daily driven vehicle.
12. Next was the Superflow muffler. This piece will provide excellent flow without making
13. After Shawn got the tailpipe mocked up in its position, we stepped back and got a solid look at how nice the system fit. Notice there’s plenty of clearance around any other parts to prevent clunks and rattles.
13. After Shawn got the tailpipe mocked up in its position, we stepped back and got a soli
14. Gibson’s kits come with the necessary clamps to finish the exhaust but we chose to make this a more permanent install by welding the system at all the joints. This way we’ll never worry about anything coming loose or leaking.
14. Gibson’s kits come with the necessary clamps to finish the exhaust but we chose to mak

15. A polished stainless tip completes the exhaust and gives a subtle flair to the Durango’s backside.
15. A polished stainless tip completes the exhaust and gives a subtle flair to the Durango
16. On the dyno it was time to see if our intake and exhaust choices were worth the money and time we put into them. At the wheels our “baby” V8 managed to go from 177.29 to 187.08 horsepower, a difference of 9.79hp. Also, torque gained 14.28 lb-ft from 219.03 to 233.31.
16. On the dyno it was time to see if our intake and exhaust choices were worth the money
17. Here’s the Durango’s dyno chart with before and after measurements. Check out those even gains across the power band!
17. Here’s the Durango’s dyno chart with before and after measurements. Check out those ev

18. Brian Smith of Autobody Color and Supply in Nashville, TN set us up with plenty of PPG products to keep Tom McWeeney, of Kustoms Inc., busy painting our door handles and hatch trim. From left to right are DCX61 Hardener, DCU2040 Clear and lastly, DBC Deltron 2000 Bright Silver.
18. Brian Smith of Autobody Color and Supply in Nashville, TN set us up with plenty of PPG
19. Tom began the arduous task of knocking down the plastic’s rough finish with a combination of Scotchbrite pads and varying grits of sandpaper.
19. Tom began the arduous task of knocking down the plastic’s rough finish with a combinat
20. All four door handles were disassembled to make them easier to paint. The rear hatch trim, shown here, required taping off and covering the chrome ram’s head emblem to prevent overspray.
20. All four door handles were disassembled to make them easier to paint. The rear hatch t

21. A few coats of high-build primer led off the process of finally getting color on the plastic bits. The high-build primer helps to further bury the texture of the plastic.
21. A few coats of high-build primer led off the process of finally getting color on the p
22. Outside the booth, Tom mixed up the PPG products per spec and once his paint gun was filled, he layered on coat after coat of the Brilliant Silver then plenty of PPG clear. Things really began taking shape here.
22. Outside the booth, Tom mixed up the PPG products per spec and once his paint gun was f
23. It’s quite a bore to color sand and polish fresh paint to a perfect sheen, so we jumped ahead to show you the awesome results of a little paintwork. With the black side trim removed and the door handles now body color, the Dodge Durango was starting to look street ready.
23. It’s quite a bore to color sand and polish fresh paint to a perfect sheen, so we jumpe

24. Our Durango’s owner wanted in on the action too, so he added his personal flair by lightly smoking the taillight lenses. With the now painted rear hatch trim back in place and Gibson’s shiny steel exhaust tip poking out from the bumper, the backside of the Dodge was complete.
24. Our Durango’s owner wanted in on the action too, so he added his personal flair by lig
25. Although the Dodge’s grille has four openings, the E&G Classic’s mesh insert is only two pieces, making for a tidy and easy to install part.
25. Although the Dodge’s grille has four openings, the E&G Classic’s mesh insert is only t
26. Moving to the front of the SUV, you can see the horizontal black slats the factory chose for the grille insert.
26. Moving to the front of the SUV, you can see the horizontal black slats the factory cho

27. A few clips and bolts were all that stood in the way of removing the stock grille shell. No specialty tools are required and you can easily do this even with modest mechanical skill.
27. A few clips and bolts were all that stood in the way of removing the stock grille shel
28. On its back, it was easy to figure out how to remove the Durango’s stock inserts. They were only held in by clips, and once released, the two halves popped free.
28. On its back, it was easy to figure out how to remove the Durango’s stock inserts. They
29. E&G Classic’s mesh had holes in strategic areas to clear the clip towers in the stock shell. After we maneuvered the mesh into place we drilled a few 1/8-inch holes as per the instructions.
29. E&G Classic’s mesh had holes in strategic areas to clear the clip towers in the stock

30. Screws were then turned into the holes holding the stainless mesh firmly where it belonged.
30. Screws were then turned into the holes holding the stainless mesh firmly where it belo
31. Many times there are little tricks of the trade for making your vehicle look just a smidge better during certain part installations. In this case, it’s the painting of the front of the core support and bracing, as well as the radiator and AC condenser. Normally we would have chosen a satin or chassis black but we happened to have plenty of gloss black handy so that’s what we used here.
31. Many times there are little tricks of the trade for making your vehicle look just a sm
32. We were about to call the project good enough when we were innocently perusing the local sale ads on the internet. Lo and behold, we came across these 22-inch Boss 304 wheels shod in 285/45R22 Nitto NT420 tires for a nice deal. After some shrewd negotiating, this little guy talked us into an offer we couldn’t resist.
32. We were about to call the project good enough when we were innocently perusing the loc

2008 Dodge Durango Modifications Satisfied Overall

Closing Thoughts
Although the 4.7L PowerTech V-8 performs admirably, it is no powerhouse. With that in mind the nearly 10 horsepower and 15 lb-ft of torque added by the True Flow intake and Gibson exhaust are noticeable. Gibson prefers to improve both power and sound, and the Superflow muffler in our kit sounds just a bit louder than factory with a nice bass tone to it. It’s just enough to be noticeable and ideal for your everyday driving needs. Since the intake is still breathing from the stock air box, it retains all its over-engineered factory conveniences plus the benefit of a direct path of air now; all the power with no suction noises under hood. With Tom McWeeney of Kustoms Inc’s handy paintwork, our Dodge can now roll down any boulevard not looking the under-optioned sibling it is. And the Boss wheels wrapped in Nitto tires bring not only looks, but also a nice jump in performance. Corners can now be handled without all the excitement of the stock sidewalls nearly folding in half. Driving down the freeway is great too; the Nitto tires are night and day difference in the noise department. All in all we managed to keep a low budget, add smart options, and do it all for a low price that brought high driving value to the Durango.