What do you all think??
 

Ok. I have a 2004 crew cab pickup with a stock 5.3 in it. I'm sick and tired of the gutless engine. The wife won't let get a different truck so I'm gonna have to uprade this thing. I'm thinking about putting headers, with magnaflow Y pipe and cats, and then duel magnaflow exhaust pipes out the back. Then using either hypertech max energy programer or black bear performance. Any ideas if this will work? Any ideas of how much horse and torque this may add? Also thinking of swapping the heavy old fan for some electric ones. I'm wanting maximum power and torque out of this tiny engine without having to change the internal engine parts. Any input or ideas is appreciated.

What rear gear ratio do you have now? Hard to beat a gear upgrade bang for the buck for some seat of the pants HP. Yes I know it doesn't actually provide more HP, but it will feel like it.

Of what you have listed the tune would be the first thing I would do. I have used BlackBear and they work real well. The exhaust upgrade will be very expensive for the gains you will see.

The 5.3 should have decent power. Do you think it is running right?

Yep, it runs fine. And it only has 55,000 miles on it. I'm not sure what gears it has in it. I'm not real confident in changing the gears in the front and rear differentials. Not sure I can tackle that job.

Improving it's breathing in and breathing out, and giving it a performance tune will definitely make it seem like a new truck. (it's cheaper then a new truck)

Oh I didn't realize you had a 4WD. That definitely adds a little more to the job. Call Justin at BlackBear then I think you will be pleased.