New or rebuilt injectors

[Big T]

This is a huge part of why I say the two set method.
You have two rigs that run the 6.5- buying a new set now & learn to do it in whatever down time you get. 1/2 hour here, 45minutes there. 10 hours into it, you can swap in the set and truck never has down time. Little by little you learn the best pop setting for the two trucks, not just one.

First time set at say 2000 psi and go into the 94. Get the mpg & 0-60. Rebuild the ones from the 94 in mean time to 2100. Then pull the 2100 set and put them in the 99. Now rebuild the 99 set to 2200 as you can. Get 0-60 mph & mpg in both trucks during normal use. The 2200 goes intk the 94, the 2100 coming out of 94 goes into 99. Keep the circle going.
You’ll learn within a year easy what each differently set up truck wants.

I never seen this done and people not gain 1.5 -2 mpg. Unless the engine wa flat worn out. Even then still saw 1mpg. You have to decide if the mpg gains and smoother running engine adding to engine life is worth it. Balanced is not a easily figured amount of added miles but our testing in the 90’s said roughly 5% injectors and 10% if entire engine balanced but that is starting from brand new and that was based on 4 trucks left stock, 4 injectors only, 8 fully balanced- all ran similar routes, similar miles per year. Percentage is me rounding off to dedicate to memory. And the fully balanced includes perfect bearing & ring gap not just mass production.

The ‘94 has injectors that were built by Badger Diesel using Bosch nozzles and 2300 psi pop pressure. They have about 50K miles on them.

The ‘99 has new Bosch India from Quadstar with 2,300 miles on them. I will work on getting a new set.