Looking for a little more torque towing up long hills at about 50mph. Tach's usually around 4500-5000 when I could use more. Not looking to spend as much as a turbo charger and don't want to risk over working the existing stock parts

Air-intakes, tuners, exhaust mod etc. What are the best lower cost options that are also unlikely (or less likely) to hurt the vehicle?

Thanks,

 

You may be able to find 5-10% more torque with a tune. Switching that 3:73 rear end to a 3.73:1 rear end will probably net you more torque as well.

 

Cheap, Durable, High Torque.....pick two.

Average costs:
Intake: $450
Tuner: $600
Exhaust: $800

Total: $1850

For the best value, spend a little more and regear the truck to 4.30. This would give you 13% lower gearing across the board before even touching the engine.

Getting into more detail, think of the transmission and diff as mechanical advantage whereas the engine is more like an air pump. With the engine putting out more power (torque and hp), it will move more air in and out, also using more fuel to do so. That said, the higher power engine still has to work with the same gearing as before but work harder to move the truck/trailer. Re-gearing gives you mechanical advantage. Providing the same torque & hp as today, the engine actually has to work less (potential fuel savings) to move the same mass. If you end up unhappy with a regeared truck then you can start throwing tunes, intakes and exhausts on it.....but you'll already be set up with the best gearing.