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6.5L Diesel Engine Discuss the 6.5 GM diesel engine & associated components. Automatic transmission questions & problems belong in the 4L80/85 - 4L60E - 6L90 Transmission Forum

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Old 10-07-2019, 01:41 PM   #1 (permalink)
grtpumpkn
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I need a 6.5 guru

I have a 1996 chevy 2500 with a 4L80E trans that has a blown 6.5. I have the opportunity to buy a 1995 3500 dump truck with a standard shift that has a lower mile 6.5L. I can't find anywhere on the internet to tell me if these two engines are the same. I seen forums that say the 94&95 are the same in their own right, but doesn't really explain as to why. All the components on the front of my 96 and the possible donor 95, ie; alternator etc, all all located differently on each engine. I do not know if the engines are the same where the bolt holes are such as same locations and thread sizes to be able to take all the front components off the 96 and swap them to the 95?? Are the tranny bolt patterns the same from the 95 standard to the 96 automatic 4L80E to bolt the 4L80E to the 95? Despite the front parts, are these two engines the same? Are the oil cooler line ports the same thread size, in the same locations? Is there anything different as far as oil pressure switch, sensors, what makes the fuel pump on the frame operate, anything at all that would make this either not a good swap, or I would need to know to make the 95 work in the 96 truck properly? Or will it not work all together and I should not buy the 95 truck at all. The 95 truck will not start because the prior owner got wire chopping happy to where there is no juice to the glow plugs, he cut in a cheapo ignition switch hanging from the column. I tried putting power to all the wires that went to the original switch, but could not get anything else, like glow plugs, to work. I heard it turn over, sounds like it wanted to maybe kick with starter fluid, but didn't! I even hot wired the pump on the frame, prior owner claimed that the pmd was new and it has been relocated, but still nothing,, but it turned easily, did not have any noises and only supposedly has 80k miles on it (says the speedometer)! So, with that said, and the engine actually looks clean yet, I am hoping wired properly it would start. But if these are 2 totally different engines due to year or transmission bolt pattern, etc.., I do not want to waste the money buying the 95 and taking that chance. I am really hoping to find maybe someone who worked a GM dealership in the 90's who really knows their stuff and these 6.5's inside and out!! If you are out there,, and can help me with these questions,,, oh thank you!! Thanks to you all for reading my dilemma and I hope the Guru I seek is among you!

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1996 chevy 2500 6.5L
4L80E trans

Last edited by OkDually; 10-07-2019 at 01:48 PM. Reason: prefix/sig
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Old 10-07-2019, 02:05 PM   #2 (permalink)
Glagulator
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Welcome.
The engines are the same except for the accessories.
The oil pressure switch location may be different but no problem to adjust.
I would do a compression test on the donor before installing.
What is wrong with the 96 engine?

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99 CREW LONG SRW C3500 work truck 199k+ mi. orig. motor & trans 4.10, modded engine harness, new oil cooler & lines, all new front end parts and poly bushings, trans poly mount, all new brakes.
96 SUBURBAN K2500 wife's truck 210k+ mi. orig. motor & trans, 3.73...
95 C2500 Suburban 6.5td HO w/p, timing set, HB & pulley, all rubber hoses, modded engine & main harness, converted to OBD2, PMD to bumper...
95 C1500 Suburban 6.5td rebuild tranny, convert to DB2, replacing as many parts as I can.
96 C2500 Suburban 7.4L converting to 6.5td w/ DB2, 4L80, 3.73
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Old 10-07-2019, 02:13 PM   #3 (permalink)
OkDually
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Quote:
Originally Posted by grtpumpkn View Post
I have a 1996 chevy 2500 with a 4L80E trans that has a blown 6.5. I have the opportunity to buy a 1995 3500 dump truck with a standard shift that has a lower mile 6.5L. I can't find anywhere on the internet to tell me if these two engines are the same. I seen forums that say the 94&95 are the same in their own right, but doesn't really explain as to why. All the components on the front of my 96 and the possible donor 95, ie; alternator etc, all all located differently on each engine. I do not know if the engines are the same where the bolt holes are such as same locations and thread sizes to be able to take all the front components off the 96 and swap them to the 95?? Are the tranny bolt patterns the same from the 95 standard to the 96 automatic 4L80E to bolt the 4L80E to the 95? Despite the front parts, are these two engines the same? Are the oil cooler line ports the same thread size, in the same locations? Is there anything different as far as oil pressure switch, sensors, what makes the fuel pump on the frame operate, anything at all that would make this either not a good swap, or I would need to know to make the 95 work in the 96 truck properly? Or will it not work all together and I should not buy the 95 truck at all. The 95 truck will not start because the prior owner got wire chopping happy to where there is no juice to the glow plugs, he cut in a cheapo ignition switch hanging from the column. I tried putting power to all the wires that went to the original switch, but could not get anything else, like glow plugs, to work. I heard it turn over, sounds like it wanted to maybe kick with starter fluid, but didn't! I even hot wired the pump on the frame, prior owner claimed that the pmd was new and it has been relocated, but still nothing,, but it turned easily, did not have any noises and only supposedly has 80k miles on it (says the speedometer)! So, with that said, and the engine actually looks clean yet, I am hoping wired properly it would start. But if these are 2 totally different engines due to year or transmission bolt pattern, etc.., I do not want to waste the money buying the 95 and taking that chance. I am really hoping to find maybe someone who worked a GM dealership in the 90's who really knows their stuff and these 6.5's inside and out!! If you are out there,, and can help me with these questions,,, oh thank you!! Thanks to you all for reading my dilemma and I hope the Guru I seek is among you!
Welcome to DieselPlace

The engines themselves are the same. The exceptions are the 95' is OBDI and the 96' is OBDII.
When the OBDII transition happened GM changed the location of the Alternator over to the Passenger side and the AC to the Driver's side and installed an advanced ECM for the electronics to be monitored

The OBDI systems used the OPS(Oil Pressure Switch) to deliver power to the lift pump causing lots of stress on the OPS causing premature failure of the lift pump and OPS.
GM corrected this in the 96'+ models and added a relay to take the load off of the OPS.
The OPS location also changed slightly from 95' to 96'
the 95' model year OPS are easy to access and the 96' model is a pain in the butt to get at because they moved it under the #7 intake finger and angled it making it very hard to service.
The Oil Cooler line sizes changed in 1997 to 1/2" ports

the 95/96' years should have the 3/8" ports

IIRC, the differences for the trans will be determined by 2 or 4wd vehicles
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1996 K3500 6.5L,( "F" Eng #141 cast block) 5 speed manual, crewcab, dually longbed: 208,000mi.
Diamond Eye 4" Turbo Back Exhaust w/2.5" Flo-Pro Crossover
AirDog II DF165 w/ tank sock delete - XDP
TD-Max boost controller - Kennedy Diesel
OPS extension hose - Leroy Diesel
Glow Plug Harness- PT Wiring Solutions
Glowshift Maxtow EGT,Boost, Fuel gauges
Boost & Fuel Pressure Bolts - Leroy Diesel
2/0 Battery Cable Upgrade - PT Wiring Solutions
PMD w/#9 resistor and Re-Location Kit, mounted to bumper - Leroy Diesel
GM-5 Turbocharger
4.10 gear ratio
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Old 10-07-2019, 06:56 PM   #4 (permalink)
grtpumpkn
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Thank you OKDually! They are both 4wd, just one auto and the 95 standard. So, to be sure of what you are saying when you say the engines are the same,, all bolt holes in the front are the same , so I can just swap all the 96 alternator and a/c and all right over to the 95 engine with no issues?? And all the OBDII stuff that may be needed for the 96 will also transition into the 95 in the same locations, except of course the oil pressure switch.? And Glagulator,, I will do a compression test! Thank you for that! Sometimes the simplest of things to do are overlooked until someone else says it,, then I smack myself in the head and think, Duh,, I shoulda thought of that!
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1996 chevy 2500 6.5L
4L80E trans
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Old 10-07-2019, 07:07 PM   #5 (permalink)
JMJNet
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One consideration that you need to make is to replace the oil cooler lines with a better one such as the one from Leroy.

The quick connect that attached to the block often failed ruining the engine.

The new threaded connection is very easy to install on the engine block when engine is out.
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Heath Turbo-Master
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Old 10-07-2019, 07:10 PM   #6 (permalink)
grtpumpkn
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Thank you JMJNet,,great suggestion! I also read I should change to a fluid dampener as well.
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1996 chevy 2500 6.5L
4L80E trans
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Old 10-07-2019, 07:24 PM   #7 (permalink)
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Quote:
Originally Posted by grtpumpkn View Post
Thank you OKDually! They are both 4wd, just one auto and the 95 standard. So, to be sure of what you are saying when you say the engines are the same,, all bolt holes in the front are the same , so I can just swap all the 96 alternator and a/c and all right over to the 95 engine with no issues?? And all the OBDII stuff that may be needed for the 96 will also transition into the 95 in the same locations, except of course the oil pressure switch.? And Glagulator,, I will do a compression test! Thank you for that! Sometimes the simplest of things to do are overlooked until someone else says it,, then I smack myself in the head and think, Duh,, I shoulda thought of that!
Transfer just the 96' engine over and install all the 95' accessories onto it.

The only problem you will have is the Manual trans install.
You will need to find a 95' ECM with manual trans programmed EPROM or have the ECM reprogrammed to the manual trans.

Or you could install the 96' engine, trans, complete engine harness, and ECM over.
You will also need to replace your IGN switch over for the manual trans option.
__________________
1996 K3500 6.5L,( "F" Eng #141 cast block) 5 speed manual, crewcab, dually longbed: 208,000mi.
Diamond Eye 4" Turbo Back Exhaust w/2.5" Flo-Pro Crossover
AirDog II DF165 w/ tank sock delete - XDP
TD-Max boost controller - Kennedy Diesel
OPS extension hose - Leroy Diesel
Glow Plug Harness- PT Wiring Solutions
Glowshift Maxtow EGT,Boost, Fuel gauges
Boost & Fuel Pressure Bolts - Leroy Diesel
2/0 Battery Cable Upgrade - PT Wiring Solutions
PMD w/#9 resistor and Re-Location Kit, mounted to bumper - Leroy Diesel
GM-5 Turbocharger
4.10 gear ratio
OptiLube summer + Formula


Proud member #1039 of The 3500 Dually Club

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Old 10-07-2019, 07:33 PM   #8 (permalink)
grtpumpkn
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Oh no,, I am only taking the engine out of the 95 to swap into the 96 ,, not the standard tranny from the 95! I am keeping the 4L80E and everything the 96 came with,, I just was hoping to take just the engine out of the 95, strip everything off of it and install all the 96 components on it and putting it in the 96 ! Thats it! I just needed to know if I could do that? if the auto tranny in the 96 would bolt up to the 95 engine, as i am keeping the tranny and everything that came in the 96 just as it came! Just an engine swap!
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1996 chevy 2500 6.5L
4L80E trans
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Old 10-07-2019, 07:50 PM   #9 (permalink)
OkDually
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Quote:
Originally Posted by grtpumpkn View Post
Oh no,, I am only taking the engine out of the 95 to swap into the 96 ,, not the standard tranny from the 95! I am keeping the 4L80E and everything the 96 came with,, I just was hoping to take just the engine out of the 95, strip everything off of it and install all the 96 components on it and putting it in the 96 ! Thats it! I just needed to know if I could do that? if the auto tranny in the 96 would bolt up to the 95 engine, as i am keeping the tranny and everything that came in the 96 just as it came! Just an engine swap!
Sorry about that..

You should be able to transfer everything over.
The only thing I am not sure of is the Engine harness fitment with the change over on accessories for 96'

Worse case scenario is that you just reuse the 95' accessories onto the donor motor.
IIRC, The trans should mount up.
You'll have a better visual when you get there on disassembly of the donor and the blown motor.
__________________
1996 K3500 6.5L,( "F" Eng #141 cast block) 5 speed manual, crewcab, dually longbed: 208,000mi.
Diamond Eye 4" Turbo Back Exhaust w/2.5" Flo-Pro Crossover
AirDog II DF165 w/ tank sock delete - XDP
TD-Max boost controller - Kennedy Diesel
OPS extension hose - Leroy Diesel
Glow Plug Harness- PT Wiring Solutions
Glowshift Maxtow EGT,Boost, Fuel gauges
Boost & Fuel Pressure Bolts - Leroy Diesel
2/0 Battery Cable Upgrade - PT Wiring Solutions
PMD w/#9 resistor and Re-Location Kit, mounted to bumper - Leroy Diesel
GM-5 Turbocharger
4.10 gear ratio
OptiLube summer + Formula


Proud member #1039 of The 3500 Dually Club

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Old 10-07-2019, 08:04 PM   #10 (permalink)
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" I heard it turn over, sounds like it wanted to maybe kick with starter fluid, but didn't!"

It is highly recommended to NOT use starting fluid with these engines. You can do a lot of damage very quickly. Glagulator or OKDually could probably tell you exactly what can happen if you do.

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'95 GMC Sierra 6.5TD C2500 2x4, reg cab, long box, 4L80E, 3.73 rear, VIN F, L65, 120K. Mods: DE 4" exhaust/crossover, WW2, PMD relocate, Dmax fan/clutch, HP air filter, Fluidampr, B&M Trans/Diff covers.
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