Iknow Its a long read.
I run a 2003 international 4300 DT 466E 2002 built non EGR engine with an alison 2000 family trans, 5.29 city gears as per line set sheet bought it used I probably would be able to get better mpg with taller gears and lower the rpms. 24 foot aluminum morgan dry box, maxon steel lift gate, 10,000 lb payload 15,350 lbs empty at the curb 25,500 GVW.
I average 9.5-10 mpg both city and at 63 mph and 2000 rpm. Unfortunately I wont win a drag race but the milage is decent and I specialize in North east regional work lots of hills usualy not a problem as long as I get the RPMs right if I take on somthing steep like 6% overall it works for me.
1) I manage to pick up one MPG by using Howes Lubricator and anti jell apx 10 oz per 50 gal at fill up Yep, year round it will help to keep from frying your injectors a $3,000 pluss fix, and might up your mpg.
2) High Quality Filters screw what the dealership wants Wix or Carquest and NAPA filters, thier filters are made by Wix only the lable and price are diferent air, fuel, and oil WARNING If you run with an Allison Transmission only use Allison spin on for the trans and trans synd fluid. Change out the fuel, air, and trans filters at most every 50,000 miles more if you crud them up quicker its a good idea to keep a of filters on the truck just in case. If you cant buy fuel from regular sorces consider a water block fuel filter or inline sepporator diesels dont run on water yet.
I dont care what you saw on you tube I saw it too.
3) I run dino lube in the crank case and spring the 30 bucks for a botle of Lucas oil additive I run at roughly 10% additive or 10 to 12Gal lube to 1 gal lucas if anything the lube oil holds up better.
You will burn off allot less oil you might get the same results as synthetic Besides, at two to three times the cost for an oil change and only with oil testing I cant justify the cost for mabey six to eight thousand miles betwene changes. Spirng for lube oil sampling at oil changes theyre worth it as they will tell you whats going on inside the engine. Espicialy if you extend your lube intervals otherwise follow manufacturers specs especialy with newer engines.
4) For the Exhaust I upgraded the mufler to a Trux series mufler stock in and out for better flow
and lower exhaust temp. Carquest carries this brand.
5) Make sure the fan cluch works right check it at least weekly this saves fuel, keeps the engine cool besides, you dont want the fan walking through the radiator and everything in front of the motor very ugly and expensive.
6) I do the lucas fuel tune up when I change the fuel filter it works dont worry it will burn just fine.
7) Keep the truck alligned at least once a year more often if you tend to throw it out due to poor driving habbits hitting a major crater, front or rear end work, or buying new rubber. And tire pressure.
Other than that, just knowing your equipment and driving habbits like speed is all I can sugest.
