Well, friends. We've been through a lot together, and I cherish the times we've had together. No...no...nobody has died, and the 'ol 6.5 still runs great. The 4L80E, however, has burned up AGAIN a little over 15 months ago now, and I've decided to go on a quest for :ro)MORE POWER!!!:ro)I've been in Iraq for the past 15 months now, and have been putting together the pieces for my 12 Valve Cummins Swap...I'll be sure to post the swap as things progress...Also, I haven't decided on what to do with the 6.5 quite yet, either...the engine is in excellent mechanical condition and has been started monthly since I left to make sure everything stays wet.

I 'think' I have most of the loose ends tied up as far as big parts go thanks to the guys over at AutoWorld. I ended up ordering their motor mounts, brackets to use the GM accessories, a pulley, a new timing cover, a new valve cover, and belts. I haven't seen them yet, but before they would make anything, they had me send them pictures of both, my Cummins engine and the accessories from the GM to make sure they mocked everything up for the right parts. There was a scheduled race a week after I finalized my order, that their fabricator was getting ready for. Even with knowing that I wouldn't be home for a month, they made my order a priority and my parts were at the house in like...8 days. So far, I am more than happy with their customer service...

In addition to the brackets, mounts, etc, I am using the A518 transmission and transfer case that came out of the doner truck that I got the engine from. I have also ordered a 31x12x4 intercooler and an aluminum radiator that's a little narrower than the stock one (I think the new one is 26.5" wide) to make sure I have plenty of room for the piping.
I also ordered a MSD-2225 fuel pump and an external pressure regulator to make sure I'm pushing enough fuel when I get her started. Has anybody used this pump? Any issues with using it with diesel fuel??

What have you guys ended up using for a downpipe? Is the stock one worth keeping or should I start looking for someone to build one to fit in the truck? I'll end up upgrading before long (once it's running) and I've gotten a bigger turbo.

Traitor :D:D:D

I'm sure one of the guys will put the 6.5 to a good home, (2) 4l80's :eek::eek::eek: in 15 mos, I'm still on 1st one and it's pulling 18K every now and again, what you been pulling is your trans cooler flowing, what kind of trans temps you been seeing, was 2nd trans a rebuild or junkyard swap, 4l80's are usually pretty stout.

I never ran an external trans cooler, or a guage (I ALWAYS WILL now, though) and the first one didn't burn out. The first one...When I had the engine replaced, I found that the bellhousing had broken away from the engine and was literally just resting on the 2 pegs in the block and the crossmember.

The second one, I was driving down a huntin trail when the ground opened up and swallowed the truck. I think the water/mud screwed with the wiring harness, and 3 days later, I was driving home and it wouldn't shift out of 1st gear...by the time I got 2 blocks from the house, it wouldn't move at all...I towed it home from there with my 4-wheeler and cleaned up the wiring, but it was too late. It would shift after that, but it would shudder real bad under a load and slip real bad. Once it warmed up it wouldn't move at all again.

oh ya...the 2nd was a rebuild...that IIRC cost me about $2800!!!

ouch mine I built up with HD clutches, shift bodies etc. before I started towing with it was $2200 with new torque converter, was in good shape when I tore it down but 18K is tall request so i wanted to beef it up and know it was in good shape since I was 2nd owner, rebuilt at 60k and now am at 146K on that rebuild, but I don't play submarine with mine either :D

I try not to...but it doesn't always work out that way. I was going down what appeared to be a well traveled access road...and in the dark, I guess I missed where a few guys have bypassed the hole I ended up in. I was just driving back the road, went through a few puddles that were about 6-8" deep, and about the 4th or 5th one (just enough I got comfortable with the water across the road) I found the hole I didn't want to go through. The next thing I knew, there was water about 1/2 way up my grill. To make matters worse, it was COLD water and the front actuator valve wouldn't engage, so I had to winch my way back out. GO FIGURE!

Jimmyt's new ride

Access road or tank trail? Or maybe a crater from a well misplaced Howitzer round by one of our Guard units.:)

...but I don't play submarine with mine either :D

But you came real close IIRC....:eek:

Actually, now that I think of it, isn't your Sub a former "sub?"....:D

chi...where do I have to go to pick one of them there thingey's??

Actually, UNFORTUNATELY it was NOT a tank trap! If It had been, I wouldn't have been kickin myself in the a$$ so hard! It really was an access road onto state hunting property. Really, guys!

Wheelin on tank trails is hard as heck on a truck...and illegal...er...umm...so I've heard! LOL A ;) "friend" ;) has went through a tranny, a transfer case, and 3 rear ends because of them darn tank trails.

No I don't think it went under water more like it got roof bashed in busted out glass and lots & lots of rain got in it, turns out the body repairs were mediocre some frame to body alignment issues, so rather than make a lame dog hunt, I just got another body, just gotta figure how to get it from Il to Ms now

Hey Jimmyt are you home yet or on the way?

I also ordered a MSD-2225 fuel pump and an external pressure regulator to make sure I'm pushing enough fuel when I get her started. Has anybody used this pump? Any issues with using it with diesel fuel??

.

If you putting a 12V in, the P-Pump trucks have a mechanical LP bolted to the side of the block, so there is no need for an electrical pump at all.
as for using GM assorys on a Cummings. It would be easier to leave the dodge alt/power steering stuff on there...or did I miss understand your post??

Oilburner, I've not made it home yet...some pretty bad sandstorms kept us grounded, but I should be back in the area within a day or 3.

Ya, I know about the mechanical LP for the P-pumped motors...but I ended up with a VE engine for a price I couldn't resist.

Actually, for fitment purposes, I would still have to relocate the dodge alt, and wold have to figure out how to make the dodge A/C work with the GM setup...The relocation is due to clearance issues with the front crossmember, and the dodge alternator is not internally regulated like the GM alternator is.

Home yet?

thanx for serving if the USA armed forces. even makes some of us canadians feel a little more secure. regards Ed

Oilburner, YES I AM FINALLY HOME!!! I got home this past Sunday, and have been running ever since. Between working on Dad's dump truck and tearing into mine, I have been elbow deep in grease since I got up Monday morning. I'll send you a PM. Give me a ring sometime...

Edzzd, It's all a part of the territory...Thanks for showing your gratitude, though. Far too many people act as if they don't care or if we're doing something wrong...

As for the swap. It's going well. With the extra work the 'Ol Man threw at me with the dump truck, I haven't gotten as far as I'd expected. Progress is being made, though...I've got everything disconnected and the entire front clip off now. I spent today building an A-Frame to jack the engines up and down, and should be pulling the engine tomorrow. I've posted a few pictures of before and where I'm at now onto Photobucket...the link is posted below. I've stripped everything off of the front of the truck, including the radiator support. It's not out in the pics, because there's an A/C line that I can't get to bust loose...I'll work on it a little more tomorrow...

http://s265.photobucket.com/albums/ii224/jimmyt83/

How is the swap going?

Just let me know if you need somewhere to sit that engine. I'll back the truck right under neath it and haul her out of your way. :)
Hinesville...we drove there last fall and adopted our dog from the animal shelter.
I bet it gets loud down there when they start letting rounds go from the tanks? Poor old dog we adopted, he's always looking up and nervous, I think he got caught in a practice field.
Thanks for serving J.

The swap is going pretty good. The engine is in, and all of the essentials are hooked up; I still have the Rad. Core support out, so there are a few loose ends there, but it's coming together. Before I put the engine in, I removed the front diff for clearance, and then cut the diff brackets away from the motor mounts. The motor mounts I got from AutoWorld in Montana bolted into the center hole on the original mounts (on the frame) quite nicely. Today I got the torque converter bolted up to the flex plate, and spent the day waiting on a guy who was supposed to give me a hand putting the tranny in. Obviously, it didn't get done... Anyways, Tomorrow, I plan on slapping the transmission in and building the transmission crossmembers.

I've added quite a few pictures to photobucket of my progress...feel free to check them out. http://s265.photobucket.com/albums/ii224/jimmyt83/Cummins%20Conversion/

jimmy, looks great so far. Hope you can overcome the difficulties I always seem to see folks have with this. Either way i am jealous as I love those Cummins engines.

In the one pic your one buddy has it right - first his face is not visible to avoid complications for him hanging there instead of fixing the home dishwasher, and second he's got a frosty beverage, third his hands are CLEAN . . .

Thanks for your service to this country, be safe out there!:cool:

No I don't think it went under water more like it got roof bashed in busted out glass and lots & lots of rain got in it, turns out the body repairs were mediocre some frame to body alignment issues, so rather than make a lame dog hunt, I just got another body, just gotta figure how to get it from Il to Ms now

How much did the body cost?
I have a wrecked 95 that i would sell or need to find a body for.

I think I found the wiring for the transmission...was it all one harness that went across both, the engine and tranny? I did have the engine wiring harness, but didn't think it was all one piece.

I have the transmission lines ran into the bed area, and have the cooling lines ran back there as well. I don't have pictures up yet, but it's at a point now where I should be able to put the bed on, hook the tranny lines and radiator up (in the bed) and start the beast up and let her run so I can get the wiring for the oil pressure and coolant temp sensors hooked up to the stock GM gauges. If I get weird readings from the dodge sensors, I'll pull the ones out of my 6.5 and use GM sensors on the Cummins engine.

Next is to figure out the shift linkage for the transmission and to figure out the driveshaft for the rear end. I also need to get the core support cleaned up so I can bolt it back to the frame now that the engine is in and running.

My 8-lug conversion for the SF axle I had planned isn't going to work the way I wanted it to. I thought I had all of the pieces, but upon putting it all together, I found out that the 2WD semi-floater 14-bolt is 2" narrower than the 4WD version, and I can't find any axle shafts around here that I'm willing to pay the prices they want for them...UNLESS of course, someone not too far away happens to have a 14-bolt SF that they're willing to swap axleshafts with....I've decided to just do the disk brake conversion on the rear and keep the 6-lug shafts. Once the truck is running and I have all of the bugs worked out, I'll find a 14-bolt Full Floater to put in. It's not really a priority right now, as my fundage is running a little low, and there's nothing wrong with the rear end I have now. I'll have to run 6-lugs on the back, and 8-lugs on the front for a while, but it's only going to be temporary.

I just ordered my suspension for both the front and rear, as well as my crossover steering setup for the front. Once that comes in, I'll be able to button this thing up and get 'er on the street. Overall, I'm expecting about 10" of suspension lift and 3" of body lift...that should be enough to put me just about right to run the 39.5" Boggers that I want to run. Once I get the Dana 60 in the front and she's sitting as tall as she's going to be, I'll have to modify the transmission crossmember to clear the front driveshaft. It's not going to be a major ordeal, but I do believe it's going to be in the way.

How much did the body cost?
I have a wrecked 95 that i would sell or need to find a body for.

$1350 for non wrecked minor rust 96 K2500 rolling chasis no engine or trans, was originally listed for $1500 guy never contacted the seller so it got relisted as $1350 buy it now, I snagged it up ASAP, 800 to ship from Illinois to Ms, I'll be parting out some of the suff I don't use between the 2 after I get the swaps finished.

Gives me hope! My dad bought a new Dodge and donated the 97 to the farm. I've been wondering what to do with it. Just couldn't make myself drive a Dodge, but a Cummins powered 96 Chevy K3500 would be a whole nother story.

The Cummins swap has went a lot easier than I expected it to. One thing to keep in mind if you decide to dive in and do the swap is that the balljoints and torsion bars on the IFS trucks aren't quite up to par when it comes to supporting the weight of an 1100 pound engine...sure, it'll support the weight for a while, but the front end will eventually start to sag and ball joints won't last as long as they would with the stock engine in the truck. Of course, the 1 ton front suspension is a little bit heftier than the little-bitty 1/2 ton suspension that I pulled out of mine. It'd probably be alright for a little while on a farm truck, though.

I bought motor mounts and accessory brackets to run the stock GM alternator and A/C compressor...that cost me about $800 bucks. Other than that, I don't really have much else into the cummins swap itself... I don't have my driveshafts made yet, either...where I used the dodge tranny and transfer case, the lengths and u-joints are different than the stock GM ones.

If you lived closer to me I would give you my 14 bolt FF with 4.10's and the front diff.

where are you at...screamin?? I make trips up/down the east coast pretty regularly...

PM Sent

Progress is still being made, but I finally hit my first speedbump. The center pulley bolt walked itself out...no big deal...I had to take it off anyways, because I didn't press the pully on far enough and the belts were not riding right. All went well until I went to put the alternator back on and apparently with the pulley out of whack, there was a lot of extra stress on the alternator housing and when I went to put the alternator back on, it snapped the bottom bolt hole completly off. OOPSE!!! I guess I should have pressed the center pulley on further!

Oh ya...I just re-ready my thread and I forgot to mention that in order to mate the transfer case up to the tranny, I had to completely remove the torsion bar crossmember. The case wouldn't even mate up to the tranny with it in place.

Otherwise, all else is going well. My suspension should be in this week as well as the crossover steering setup. Today, I hooked up the accelerator pedal and fabbed up a accelerator bracket to run the cable to inside of the truck. The truck was originally a "drive-by-wire" truck and the TPS mounted directly to the accelerator pedal. I removed the TPS from the pedal assembly and took a piece of 1/4" plate steel and cut a slot to fit over the little key that turned the TPS. THe bracket ran straight up from there to where the cable fit through the firewall. I bought a $29 universal trottle cable from auto zone and cut it to fit what I needed. It seems to work like it's supposed to and looks great. I also got my brake disks onto the axles and the rear end is all back together. I haven't welded on my caliper brackets yet because I had to get the rear end back togethr to move it around the yard. Somethin' about city ordinances and my yard looking like the local boneyard. GO FIGURE! Oh ya, and the bed is back on and it's starting to look like a truck again! I'll get pictures tomorrow and post them up.

On the rearend.. if you look at the 73-87 chevys the rear on the 4x4 is 2" narrower by design,

So if you are running a straight axle front the one you want is the 2wd axle for 88-98.. as it is the same width as the 73-87 4x4...

Ran a 95 2wd 14bolt in by early blazer for years...

Well guys, I've finally gotten some progress to post. Over the past week, I've gotten the disk brake conversion completed, I've built my own shackle flip, and my springs finally came in. I haven't done anything with the front yet, but I've finished up (except for some finishing touches) the shackle flip and installed the rear 5" springs. All I can say is HOLY COW!!! I didn't expect for it to be quite this tall, and it's not even finished yet! I have already updated my pics on photobucket to reflect the recent changes...and separated my pics into 2 different folders; one for the Cummins Conversion, and one for the Solid Axle Swap.

Cummins Conversion... http://s265.photobucket.com/albums/ii224/jimmyt83/Cummins%20Conversion/

Solid Axle Swap... http://s265.photobucket.com/albums/ii224/jimmyt83/Solid%20Axle%20Swap/

As for the axle selection...are you talking about the 14-bolt SF or FF being wider in the 2WD models? I've decided to leave the SF axle alone for now, and leave it 6-lug with disks. I'll probably have the front built before I find a FF axle, and am not afraid to run it with 6-lug rear and 8-lug front axles until I find one and get it built the way I want it. I'm not talking more than a month or two...

I know...an update is LONG OVERDUE...sorry guys. I've had a lot going on, and usually don't stop working on the truck till it's dark outside. Anyways, here are a few pics of the Cummins in place.

http://i265.photobucket.com/albums/ii224/jimmyt83/Cummins%20Conversion/IMG_0398.jpg
http://i265.photobucket.com/albums/ii224/jimmyt83/Cummins%20Conversion/IMG_0445.jpg

With the engine mounts and brackets, I found the conversion pretty straightforward. The 5.9L Cummins fit right in, and fabbing up a crossmember for the transmission was pretty simple. Once the engine was in, I jacked the transmission up until the tranny pan and oil pan were pretty much level with the frame, and was able to run a piece of "C" channel across the bottom of the frame-rail from one side to the other. I'll have to modify it a little bit once I complete the SAS for clearance for the front driveshaft, but that's no big deal.

I decided to put the radiator and tranny cooler in the bed for extra clearance up front for the intercooler. I made the plumbing for the cooling system out of 2" exhaust tubing and a few bends from the the local parts store. It is possible to get an intercooler from a newer Dodge pick-up and keep the radiator in the stock location, but I chose a 4" thick intercooler and remote mounting of the cooling system. Due to the body lift, I decided to run the tubing across the top of the frame rail, between the frame and the body. I don't have any pics of this yet, but I should have them up within the next few days.

Since I kept the Dodge tranny and transfer case, I'll be using a Chevy Dana 60 for the front axle, and will eventually upgrade the rear axle to a 14-bolt FF rear end. For now, I'm going to keep the stock 14-bolt SF rear and run the 6-lug rear shafts until I can find a suitable rear end. My SF has recently been rebuilt and I put an ARB locker in it...I haven't even had a chance to use the ARB yet.

Since my last post, I have gotten the front clip back on the truck, as well as the hood. I have the rollbar sitting in the bed, and have my cooling lines ran back to where they need to go. The radiator is hooked up, but I have yet to actually mount it in the bed.

http://i265.photobucket.com/albums/ii224/jimmyt83/Solid%20Axle%20Swap/IMG_0516.jpg

http://i265.photobucket.com/albums/ii224/jimmyt83/Solid%20Axle%20Swap/IMG_0515.jpg

I have also gotten the front springs hung using Sky Manufacturing's shackle hangers and a home-made set of spring hangers in the front...and a Dana 60 sitting proudly under the front of the truck. My crossover is hooked up, and I'm working on the turbo/intercooler. I have aquired a bigger turbo from a dump truck that I'm going to run as a bottom turbo in a set of twins, so that's going to set me back a little while in getting her on the street...BUT...SHE'S GETTING THERE!!!

http://i265.photobucket.com/albums/ii224/jimmyt83/Solid%20Axle%20Swap/IMG_0513.jpg
[img]

Was reading about your swap. I have a 95 dodge that has a Cummins 12 valve diesel in it. It runs great but I need to do some work to it oil leaks water etc. I thought about just doing it in frame but then i realized I might be able to put it in my 95 Chevy 1 ton 4x4 dually. I like the way it drives and handles better than the Dodge. but the 6.5 is just absolutely not cutting it. They both have 5 speed manual trannys. I had heard that they were the same tranny. Would you have any idea if that is so? I know the motor mounts will need to be changed and I may need a adaptor for the engine tranny. Is there any web sites to order or get some help with technical things that may pop up? Sorry for the long post but I would really like to make the swap. Any help would be appreciated. thanks Tim

Sorry it is a 94 chevy1 ton dually 4x4

the input shaft on a dodge nv4500 takes a different bearing size for the back of the crank vs the one needed for the gm nv4500

http://www.google.com/search?sourceid=navclient&ie=UTF-8&rls=GGLG,GGLG:2008-31,GGLG:en&q=cummins+forums

Try cummins forums Google search

Ya, the trannies are the same, but as Outalne pointed out, they have different input shafts...and there's more to it than just swapping the shaft. Your best bet would be to use the dodge NV-4500 that's already mated up to the motor.

As for specific sites that deal with the cummins swap...the best 2 that I have found are www.cummins-conversion.com and www.1stgen.org.

I would highly recommend the motor mounts, alternator, and A/C brackets from AutoWorld...using the GM alternator and A/C allow for an extremely easy swap, as the only wiring required is the fuel shutoff solenoid and the starter wires. The gauges and such aren't too awful bad to do, either...it's just figuring out the right wires.

So...the front shocks and right rear shocks are hung. I would have both of the rear shocks hung if I hadn't lost one of the brackets...I know it's somewhere around here...
http://i265.photobucket.com/albums/ii224/jimmyt83/Solid%20Axle%20Swap/IMG_0555.jpg
I re-did the transmission crossmember. I used a piece of 2x4 square tubing and cut the ends to make a flat surface to bolt to the frame.
http://i265.photobucket.com/albums/ii224/jimmyt83/Solid%20Axle%20Swap/IMG_0546.jpg
http://i265.photobucket.com/albums/ii224/jimmyt83/Solid%20Axle%20Swap/IMG_0551.jpg
I also got the rear disks on, but am having some trouble getting them hooked up. Somehow, I was thinking I could use hard lines to hook the calipers up, and after getting extremely frusterated, I realized that they were designed for the front...I got some front lines, banjo bolts, and washers, only to find that the banjo bolts they sold me were the wrong ones...and the parts stores are closed...GO FIGURE!!
http://i265.photobucket.com/albums/ii224/jimmyt83/Solid%20Axle%20Swap/IMG_0554.jpg
http://i265.photobucket.com/albums/ii224/jimmyt83/Solid%20Axle%20Swap/IMG_0549.jpg
http://i265.photobucket.com/albums/ii224/jimmyt83/Solid%20Axle%20Swap/IMG_0550.jpg
I had planned on some pics of the front shocks, and I also have the rear bumper built...but my camera batteries died. I'll try to get them up within the next few days. OH YEAH!! And MY BOGGERS!!! I only have 2 of them (the other 2 rims are on backorder) so I'm going to put them on the rear, and probably run the 39.5x15 TSL's I have on the front until my other two come in.

good job

looks like alot of work

thanks for keeping us posted

IT....IS....ALIVE!!!!
I took the truck around the block a few times now, and all I can say about it is WOW!!! The truck is nowhere near complete, but she moves under her own power now, and is almost streetable. There's still a few bugs to work out...but she's getting there.
Here's a picture of how I mounted the front shocks...
http://i265.photobucket.com/albums/ii224/jimmyt83/IMG_0679.jpg
I got the radiator mounted in the bed, and the home-made fan and shroud. The right side, I broke the fan blade trying to get it off of the motor, so I covered the hole with a couple pieces of rubber. Also, around the radiator to the fan shroud, I used an old truck inner tube to close it off, so the fan is sucking air through the radiator. There's still some cleaning up to do to it, and of course, I need to install another fan on the right side. Also, I built the double tube bumper for it...still a little left to do to it too.
http://i265.photobucket.com/albums/ii224/jimmyt83/IMG_0674.jpg
Here's the stance from the front. I am still waiting on the guys at Pro Comp to finish building my other 2 rims for the front, so I have a scrap set of wheels and tires on the front. Using a soap stone I drew out a couple of ideas for the front bumper, but I think I'm going to leave it alone...except for my winch fairlead and a couple of shackles in the center.
http://i265.photobucket.com/albums/ii224/jimmyt83/IMG_0677.jpg
http://i265.photobucket.com/albums/ii224/jimmyt83/IMG_0678.jpg
MMMMM!!!! BOGGERS!!!! I love how they line up with the body lines. They're on 15x14 Pro Comp 88 Series. BEWARE!!! They've been ordered for over 2 months now, and I've only gotten 2 of them. Supposedly, they should be here by next monday, but I've heard that before.
http://i265.photobucket.com/albums/ii224/jimmyt83/IMG_0676.jpg
http://i265.photobucket.com/albums/ii224/jimmyt83/IMG_0675.jpg
She TOWERS over the 'OL Lady's jeep!!!
http://i265.photobucket.com/albums/ii224/jimmyt83/IMG_0680.jpg

Are you gonna paint it Frankenstein Green? Maybe put ABINORMAL on the tailgate. Dang man, you have put mucho grande work into this project. It's a hell of a project that your finally seeing the light at the end of the tunnel. When you get done you should get a pick of it parked on top of a a couple of honda civics.:ro)
Nice!

I just got a 94 3500 hd w/ only 28,000 miles, but i also came across a ford cab over box truck w/ a 12 valve cummins in it dirt cheap.some people have no idea what they got. the cummins has a 6 speed stick shift tranny and i would love to put this motor and tranny in my chevy someday.

hold onto the cummins and 6 speed...it's well worth saving for it's day.

Frakenstein green?? I was thinking a forest green or maybe emerald color...

Ya, it's been a TON of work, but it looks like I'm getting most of the bugs worked out. The temp gauge shows 210 once it warms up...but it also shows 210, then the thermostat opens, and it drops to about 140 or so and then climbs back to about 210 and so on and so forth. I think the temp gauge is off, because it still has the Dodge temp sensor...I know for sure it's a 180 degree thermostat. I have ran it about 80 miles or so, and the steering and brakes both seem to be working a LOT better. Until the last 5 miles or so, I have had absolutely NO power steering and hardley any brakes, but they both seem to be getting better. I stayed with the Hydroboost system, and I think it just has to bleed all of the air out of the system. Otherwise, everything is working great, and seems to be getting better the more I run it.

As for parking on top of a couple of HONDA's!!! I PLAN ON IT!!! Just as soon as I get the front end hooked up and the bugs worked out.