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Old 07-18-2010, 11:02 PM   #1 (permalink)
prichmon
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Bully Dog 6.5L exhaust install on 1500

I recently purchased a Bully Dog exhaust for a 25/3500 since everything around hear seems to work on all the trucks including my 1500 (emissions excluded). I have had 2 different look at installing the unit to no avail.

The problem comes at the frame rail, body and crossover interference. It looks to me as if I have <2.5" of clearance to fit the DP. The stock is crushed to ~2/3 flow and I can't see a way without cutting/bending the frame or denting the crap out of the DP hich negates the performance gain. Any thoughts would be very appreciative.

Rich
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1994 GMC Yukon 6.5td, 4l80e auto, 354K miles, ssdiesel pmd on heat sink behind bumper, custom exhaust, flow master crossover and DP, 10 bolt 3.42 rear. Buddy chip 15psi, 93 lift 1 ton pump;aux tranny cooler, bosch glow plugs, aux 2 micron fuel filter, front and rear reese hitvh, firestone airbag rear springs, high capacity turbulator tranny pan, aux tranny filter, ARP Head studs, K47 air box, SS step bars, ball joints, front diff seals, cross drilled rotors, 2300+psi injectors,

SOLD...1994 c1500 ext cab sb 6.5td, 4l80e auto, 200K miles,

SOLD....1995 K1500 ext cab sb 6.5td, 4l80e auto, 286K miles,
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Old 07-18-2010, 11:17 PM   #2 (permalink)
fusion
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Sorry, I can't help you but I'd like to know the price of your Bully Dog. I'm going to get it too.
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Old 07-18-2010, 11:23 PM   #3 (permalink)
Crazy
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Quote:
The problem comes at the frame rail, body and crossover interference. It looks to me as if I have <2.5" of clearance to fit the DP. The stock is crushed to ~2/3 flow and I can't see a way without cutting/bending the frame or denting the crap out of the DP hich negates the performance gain. Any thoughts would be very appreciative.

think the motor mount is had that way it won't fit
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Old 07-19-2010, 02:03 PM   #4 (permalink)
6fiveturbo
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i put my bully dog on last week had no problems
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1995 6.5 2500 4x4 5 speed 169,000 mil. vin "F". 2.25 crossover. 4" exhaust. egt gauge. new remouted PMD with heat sink. ssdiesel 40hp chip

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Old 07-19-2010, 06:12 PM   #5 (permalink)
bk95td
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Motor mounts must be in perfect condition. They can make a big difference. Even with new energy suspension mount inserts my 95 k2500LD had to have some hammer adjusting to the down pipe. That was with a hearthrob system[makes system for ss diesel supply]. The same system went on my 92 k2500HD with no denting. I just put a Diamondeye system on the 94 K2500HD in my sig. Way better fit Less than a hour to put on.
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92 k2500hd 6.5 4L80E std cab the work horse
4- 93 k2500hd 6.5 2-4L80E 2-NV4500 2-ex-cab 2 std
93 suburban gasser 4L60E Blown up-oil cooler lines 94 K2500HD 6.5td 4L80E new reman engine
94 GMC Yukon 2 door gasser
95 tahoe 2 dr 6.5 4L80E needs HG or engine
95 k2500ld 6.5 4L80E std cab bad trans
95 k2500hd 6.5 4L80E ex-cab
95 Yukon 2 dr gasser 4L60E blown engine-oil lines
2-95 K2500 Suburban 6.5TD 4L80E both need engines
97 k2500hd 6.5 4L80E std cab
97 k3500 C&C 6.5 4L80E std cab needs engine
98 k2500 hd 6.5 4L80E std cab bad trans
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Old 07-19-2010, 06:43 PM   #6 (permalink)
prichmon
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Guys please note my truck is a 1500. Somewhere I saw a pic of a 3500 DP and frame without the body on it. The P had plenty of room except for a flattened area a few inches long. My DP is nearly crushed in half due to the space limitations.
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1994 GMC Yukon 6.5td, 4l80e auto, 354K miles, ssdiesel pmd on heat sink behind bumper, custom exhaust, flow master crossover and DP, 10 bolt 3.42 rear. Buddy chip 15psi, 93 lift 1 ton pump;aux tranny cooler, bosch glow plugs, aux 2 micron fuel filter, front and rear reese hitvh, firestone airbag rear springs, high capacity turbulator tranny pan, aux tranny filter, ARP Head studs, K47 air box, SS step bars, ball joints, front diff seals, cross drilled rotors, 2300+psi injectors,

SOLD...1994 c1500 ext cab sb 6.5td, 4l80e auto, 200K miles,

SOLD....1995 K1500 ext cab sb 6.5td, 4l80e auto, 286K miles,
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Old 07-21-2010, 09:28 PM   #7 (permalink)
prichmon
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Got the bullydog installed... The dp took over an hour to wiggle and massage in place, the mid pipe touches the center driveshaft crossmember. I have massaged the bottom of the pipe and the top right as it contacts the bed. I still have to do some massaging since as I hit bumps the exhaust hits hard parts vibrating the bed.

Rich
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1994 GMC Yukon 6.5td, 4l80e auto, 354K miles, ssdiesel pmd on heat sink behind bumper, custom exhaust, flow master crossover and DP, 10 bolt 3.42 rear. Buddy chip 15psi, 93 lift 1 ton pump;aux tranny cooler, bosch glow plugs, aux 2 micron fuel filter, front and rear reese hitvh, firestone airbag rear springs, high capacity turbulator tranny pan, aux tranny filter, ARP Head studs, K47 air box, SS step bars, ball joints, front diff seals, cross drilled rotors, 2300+psi injectors,

SOLD...1994 c1500 ext cab sb 6.5td, 4l80e auto, 200K miles,

SOLD....1995 K1500 ext cab sb 6.5td, 4l80e auto, 286K miles,
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Old 07-21-2010, 10:03 PM   #8 (permalink)
bk95td
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Did you check how worn your motor mounts are? The passenger side always goes bad first because of the torque pulling it up. Stock replacements are less than $15 each at napa. It can easily raise the engine more than a inch.
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92 k2500hd 6.5 4L80E std cab the work horse
4- 93 k2500hd 6.5 2-4L80E 2-NV4500 2-ex-cab 2 std
93 suburban gasser 4L60E Blown up-oil cooler lines 94 K2500HD 6.5td 4L80E new reman engine
94 GMC Yukon 2 door gasser
95 tahoe 2 dr 6.5 4L80E needs HG or engine
95 k2500ld 6.5 4L80E std cab bad trans
95 k2500hd 6.5 4L80E ex-cab
95 Yukon 2 dr gasser 4L60E blown engine-oil lines
2-95 K2500 Suburban 6.5TD 4L80E both need engines
97 k2500hd 6.5 4L80E std cab
97 k3500 C&C 6.5 4L80E std cab needs engine
98 k2500 hd 6.5 4L80E std cab bad trans
Volunteer Foster and Transport for Retrieve A Golden of Minnesota-Golden Retriever rescue group
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