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From the factory the DT466 could be purchased in trucks with HP options up to 250-275 HP. If you choose to increase much more than that you will start to have some reliability issues.
How much you can increase depends on several isses.
The more you increase the HP the greater your cooling needs will become, especially on an uphill grade. Inceasing your HP 20% may require 100% increase in cooling capacity. Marine applications don't count because keel coolers have the whole ocean for heat exchange.
The ease of increase depends upon which pump you have. The electronic pump is a software upgrade. Inline mechanical pumps are easier to increase than the mechanical rotary type pump.
Depending on what transmission you have behind your DT466 will also determine how much of an increase in HP you can use. 250-275 HP is about the limit for MT-series Allison transmissions. More than that you will need the HT-series if you want reliability.
Stick shifts will be limited to the size of the clutch. Much more than the 250-275 HP range will require a larger clutch which may require a different flywheel.
If you have repowered a truck that didn't have the DT466 in it from the factory, increasing the HP can also cause driveline and chassis problems. The most signigicant would be the driveshaft may not be able to handle the increased HP and torque, particularly on a downshift while going uphill. You may also experience frame torque causing on starts and shifts causing your frame to crack or break.
Sounds like a load miss. Chk plug wires for deterioration and or cross firing. Wires should not cross over each other. Worn plugs load wires causing increase spark out put increasing cross firing potential
Depending on the flash you are using, 250 may be as fast as you can go. That may be the limit for the internal flash. A big external flash can go faster because it requires more power.
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