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Old 06-15-2009, 06:43 PM   #1 (permalink)
z79outlaw
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98 Chevy Cummins conversion (Pics in here!)

I started with a 98 Chevy K3500 Silverado, I bought the truck at 133,000 miles in August of 05 and the thing held together by a miracle for 10,000 miles exhaust valve broke on the #3 cylinder took out the piston. After being down for 3 months I got a used motor in it in the Fall of 06, the new engine got me through college and a new job for another 20,000 hard miles. The clutch was going out on it and finally it died in May of 08, fuel shut-off soleniod, I beleive but no matter I had already decided I was going to put a 12v in it and I was planning on cutting it up the following weekend.

The truck started with intentions of being a daily driver/puller, but I found a steal on a 05 Duramax that got priced wrong as a 6.0 gasser, during the progress of the swap and decided it would be a dedicated puller instead. Changed my mind a million times on what the final set-up will be with the motor and I'll prolly change it again. But right now, it will be a 2.6" or 2.8" puller, with the capability of changing it back to a daily driver someday with a turbo change should I decide to sell it or get out of pulling.

The motor is out of a 96 Dodge Cummins, it has a 180 p-pump on it. I retained the original GM NV4500/borg warner combo to back up the motor. Up front the original 9.25 IFS will be retained with the steering beefed up. Out back there will be a 11.5" AAM out of a 03 Dodge Cummins. I also have converted it from a DRW set-up to a SRW.

Its been along time going, and had plans of getting it going this year, but prolly wont happen been putting away money for a house, so most of the stuff I do or buy lately has been from good deals on the net I find and other budget stuff. But no excuses "Cummin on Strong" will be ready for next year.

Before the swap, and the load that nearly ripped my clutch out.





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Old 06-15-2009, 06:52 PM   #2 (permalink)
z79outlaw
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Picture of the motor in the truck after I got back from a 12 hour trip to Findlay, Ohio



I had to remove the powersteering/vacuum pump from the 96 and I sourced a hyrdoboost pump off a 24 valve cummins and mated it to the vacuum pump to run the brakes on my Chevy. I have no need for the vacuum pump and have the ports plugged but the way dodge has it set-up you have both or none.



Last picture of the 6.5 in the truck



I installed 3" body lift in my truck to make fitment better. Its not nessacary but I prefer the advantage of the body lift in the GMT-400 platform, it really makes the swap alot easier though.



Motor out of the truck.

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Old 06-15-2009, 06:57 PM   #3 (permalink)
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Motor and trans out. Plenty of room for the big 5.9 to fit.



Test fitting the new motor.



Fabbing up my own motor mount brackets. I decided to make my own bracket as it allowed me to put the wont where I wanted it. I wanted it as low as I could put it, and as far back as I could get it, so I would have the option to run a mechanical fan should I ever decided to daily drive it. The mounts from autoworld would not allow for this.



How the 1st generation Dodge motor mounts are intalled iin the frame.



Picture of the piece of frame I had to clearence to allow the motor to fit.

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Old 06-15-2009, 07:01 PM   #4 (permalink)
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Every time I would slide the motor in and out I kept getting hung up on the pinch weld between the cab and firewall I got sick of it and pounded it out of the way.



Close-up of the custom motor mounts. You can see how they bolt up to the motor and allow them to just slide over the protruding bolts on the motor mounts.



Picture of how the mounts fit and the clearence. Passenger and Drivers side.



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Old 06-15-2009, 07:05 PM   #5 (permalink)
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Picture of the motor sitting in the mounts and bolted it.



Lots of room for a mechanical fan.



And I can still fit my whole hand between the motor and firewall.

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Old 06-15-2009, 07:20 PM   #6 (permalink)
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To run a GM nv4500 you need a 96 + newer one. Other than the mainshafts they are very similar. I swapped in a 1-3/8" SBC billet input shaft that dwarfs the 1-1/8 stock shaft. I went with a SBC Dual Disk 3850 12 button Feramic plate clutch. I got all of that from Cody at Flirtn With Disaster Performance, probably the best SBC prices around. I also had to purchase a SBC upgraded hydrualic unit. It was close to perfect fit. The line was a little tight, but it worked. The main issue was that the clutch linkage from the master cylinder to the pedal was to short to engage the clutch, so we cut it and brazed a 1" piece to get te clutch to work properly.

Comparison of the inputs and the $25 a quart transmission fluid



Bad ass Rebuildable SBC flywheel with removable inserts



Picture of the Clutches



Everything installed and torqued

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Old 06-15-2009, 07:25 PM   #7 (permalink)
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I removed the box and stripped the frame down to bare metal from the cab back (planning on doing the cab forward in the winter). A knotted wire wheel, milwaukee grinder and alot of time. POR-15 2 coats, and then painted flat black to protect the POR-15. The POR adhered to the metal great where the was rust. But where it had been painted of virgin bare steel the results were less than impressive. Even following all of there techniques and using the product the recommend to use on bare metal it still didnt adhere well. But other wise I was happy with it.




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Old 06-18-2009, 10:27 PM   #8 (permalink)
05duramax073
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That is going to be sick.
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Old 06-18-2009, 11:28 PM   #9 (permalink)
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You live in the Grove too I see, I'll have it down in the area this winter, you'll have to stop by or somthing. Whats your truck look like maybe I've seen ya around
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Old 06-21-2009, 03:42 PM   #10 (permalink)
05duramax073
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I actually just traded in my DMAX. I went with an 09 Powerstroke. I know it is the enemy on this board, but I loved my DMAX. I just to good of a deal to pass up. My new truck is a 09 F350 CC with blue on top and tan on the bottom. If i get the chance in the next year I want to buy a 05-06 LLY RC LB. Build it up for pulling. But yeah I would definitely like to see the truck.
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