Hey guys, I'm new here! I just discovered this site an hour ago, and you guys look like a very informed and knowledgeable group of posters for me to learn from.

I've got a 99' W4500 (40K mi/7400 hrs!! when bought and 63K mi./8200 hrs now) that I bought 1 1/2 years ago, with a somewhat wasted motor, thanks to the bozo who owned it before me. Does anyone have any knowledge or info about whether this swap is possible? I've been dreaming about the Dmax HP & torque swapped into the 4500, as I also have an 03' GMC 2500 Dmax with an Edge juice module. I'm wondering about issues like clearance, electronics, fuel pressurization, and systems integration in general. More trouble than it's worth? Should I keep throwing money at my anemic 4HE1-TC motor? It always opperates at the 14,500 lb chassis limit in the Colorado mountains at 6000' +/- altitude?

Are there ways to pump a new 4-banger up reliably, or....Is there a simpler swap to do that will give me reliable & somewhat economical better HP/torque. I get about 10 MPG now, although it's a real toad on the highway.

Oh yeah, I almost forgot, a little obvious advice from me. Don't idle your diesel all day for 4 years with trashed oil and a thermostat stuck open like the guy who owned this truck before me!! And, pull the valve cover BEFORE buying something like this from a friend of a friend/salesman who said it was 'well maintained' by the previous owner, who was supposedly a diesel mechanic. Ya, right! -:t Thanks. Daryl

I have no clue what it would take besides ALOT of TIME AND MONEY. I don't think it would be worth the trouble. It is 6years old already and everything else is probably not up to a duramax.

Where in CO are you? You should check out a c4500/5500 with the duramax combo. I have a 5500 4x4 and am really pleased at 10k above sea level (Leadville) You are welcome to check it out.

Howard

Hi Howard, I'm in Durango. True, the truck is 6 years old, but the cab/chassis only has 63K on it and is in very good condition.The dealer mechanic in Albuquerque I spoke to at length said IF maintained, he sees these trucks go 500,000 to 600,000 mi. I would think the diff could handle some more power, although I don't at this time know if the W5500 has a heavier unit behind the same motor. When I think about the cost to re-build, or the $3K to $5K for a used (plus install) or $10K to $13K for a new motor with turbo, the cost of a used Dmax isn't that bad!

The C4500/C5500 would be nice, but wouldn't turn nearly as sharp (importantant to me) and would be big bucks. Probably more than I paid for the expensive used tool truck conversion W4500 to begin with.
I also posted this in the tech forum here after I saw it, so I'll see what some of the others think about this.

Nice to hear from someone in Colorado. BTW, I snowmobile from Eagle to Leadville and back almost every winter, possibly next week! Do you sno-mo? PM me if you wish. Daryl

I don't get on the small machines too much. I have a sno-cat):h I think you would be suprised at the turning radius of the c series. I don't know of anyone technical enough to do the swap though. I am sure it can be done. I have seen plenty of people put 350 gas chevy motors in the Isuzu NPRs which are simmillar to the W series I believe.

When are you going to be up here? I ain't going any place till spring (plow business). I will pm with my cell/home numbers

Howard

I finally got the chance yesterday afternoon to put the tape measure on all of it. The Dmax motor is to tall and too wide to fit between the frame rails and under the cab. The length was no problem. So, it looks like I'll have to live with the 4 and just do the repairs. It was fun dreaming about it though! :D Daryl

WOW man that would be sweet!! It may be possible since some of the 99 W4500s have the 5.7L V8 gas, so I think with A lot of $$$ and time you could mod it. However, I wouldn't recommend wasting you're time with that. I think the new 2005 W4500s have a better engine, the 4HK1-TC w/ 190 HP., I think its a 5.2L 4 Cyl. this would be much better in my opinion. You would prob. save a little more fuel w/ the 4 cylinder too. I run a 2002 GMC WT5500 w/ the Isuzu 6 cylinder 6HK1-TC or DMAX 7800 as it is better known. I also have a T8500 Tandem w/ a CAT 3126E 300 HP. Anyway, I think the most cost efficient improvement for you is to rebuild or change to another 4HE1-TC, in my opinion, you prob. would be much happier, Isuzu MEDIUM Duty trucks can last forever if you take good care of them.

Thanks 8500! I've been doing a lot of thinking about all of this over the Holidays. I'm wondering if the new 4HK1-TC would be a bolt-in replacement for my 4HE1-TC, if I could find a good one out of a wrecked truck. I know it's only an additional 15 HP and 40 lbs. of torque, but in my truck on the weight limit at all time, it would be a big help! Would the injection, electronics, exhaust, etc. be compatible and a bolt-in to my 99' chassis? A new cab & chassis is roughly $30K, plus I would have to swap my box and all of it's systems over (extra AC pump & lines, electrical, bumper/lites etc....)! Would be easier to just work out what I have. Any help or advice is appreciated. Thanks, Daryl

BajaDQ,


I don't know if it can be a direct bolt on since GM/ISUZU has had a lot of changes done to the Medium Duty line. With the new engine, I'm pretty sure that electrical and chassis have both been changed. I know that they have more diagnostics and equipment now such as an electronic oil level gage, etc. I am guessing there are some minor improvements done to them even though the cabs look the same. Anyway, I still think its not worth the extra work and just get a rebuild or reman engine, once its repaired it will probably be able to do the job you need for it to do.


Luke