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1991 Chevy Crew Cab "R" / "V" Conversion

Overview Gallery Discussion
ryoken said:
oooooo, hey yeah, what's going on here? ;) thanks.... :waytogo:

cool, following.. :saweet: i'll go read this....

no frame boxing?
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I don't plan on boxing the frame right now, I will add some support around the steering box when I clearance the crossmember. I don't have plans for big power for this engine, just better driving manners and fuel economy. Getting 7mpg with my big block sucks!

GWeakland620 said:
noice!!!
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Thank you!

Kay86K5 said:
keeping the GM NP205 behind the dodge NV4500? If so, swapping inputs to 29 spline on the 205?

I thought heavily about doing the Cummins in my V3500, but decided against it and have gone 8.1
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I thought about the 8.1l but I don't think it would get the "fuel economy" the Cummins will. So currently my truck has a '89 7.4 tbi and a 98' NV4500 behind it. I'm going to pull the input shaft and retainers out of the Dodge and swap them into mine, that way I keep my np205!
 
If you have a 4500 205 now what's your shifter configuration at the moment? Do you know if you can keep the 4500 in the same spot and put the cummins in and be ok?
 
obijuank5 said:
Don't leave us hanging. Lots of details please.
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Any specific details you are looking for? I will include my parts list when I can get to my computer but details on my swap are as follows.

When I bought the truck I could tell it was going to need a few things addressed like the primer pump on the lift pump leaking diesel and a oil leak from the oil pan gasket. Once I got it pulled out I found several other surprises, like torn turbo boots and leaking front gear cover.

I had made the decision to paint the engine Cummins beige to make oil leaks easier to find in the future, this started a snow ball of ordering gasket such as the tappet cover and gasket, vacuum pump gasket, timing cover gasket and front crank seal. I had to remove the injection pump to swap the tappet cover so while it was out I opened up the afc housing. Someone had run the smoke screw all the way in and cranked the star wheel some. I readjusted all of that and decided I will bump the timing up to about 15.5 degrees seeing as I had to pull the injection pump gear anyway. Fun side story, when I opened the timing gear cover to to check the KDP I found that the injection pump shaft lock nut and washer were missing! The only thing keeping the timing from slipping was the friction from the taper shaft. I also picked up a valve cover vent kit that comes off a Case IH tractor to help vent the crank case pressure and keep it from leaking oil from blow by.

For mounting the engine I am using the Screamin Seeman crossmember kit and their clutch master cylinder adapter. The last few parts have showed so hopefully when it warms up a little I can finish painting it and get everything bolted back up. The goal is to run it on my "test cart" before I drop it in, I also picked up some parts for the truck like a diesel fuel tank, diesel sending unit, materials for running new fuel lines and a exhaust pipe kit designed for a first gen cummins that I will make work.

Let me know if you have any questions and I will paste my total parts list tomorrow.
 
obijuank5 said:
If you have a 4500 205 now what's your shifter configuration at the moment? Do you know if you can keep the 4500 in the same spot and put the cummins in and be ok?
Click to expand...

I built a mount that bolts to the front part of the transmission tail housing. I will try to find a photo of it. The mounting with the Cummins will depend on where I mount the engine, I can't go too far forward without hitting the radiator and I can't to too far back because of the firewall. From everything I have heard and seen it will probably move the transmission back about 2-3 inches. Hopefully not much more...

Here are the photos.
Location
full

full

Bracket
full
 
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I think I have my swap pretty locked down but new information is always welcomed. Maybe there's something you would do different that kicks butt. I already learned about the compressor delete pulley. Never knew that existed.
I'm curious to see transmission pavement relative to current position.
 
obijuank5 said:
I think I have my swap pretty locked down but new information is always welcomed. Maybe there's something you would do different that kicks butt. I already learned about the compressor delete pulley. Never knew that existed.
I'm curious to see transmission pavement relative to current position.
Click to expand...

Are you planning on running fuel lines? I am going to run mine down the driver frame rail to keep it away from the exhaust heat and that's the side the lift pump is on anyway.
 
So here is the list, I will go through and organize it and add the links back in tomorrow.

X-member

Screamin Seeman Crossmember kit Link ($625.00)
Dodge clutch master cylinder adapter plate Link ($30.00)

High mount A/C and Alternator Parts
Cummins water inlet connection PN 3941929 Link ($35.25)
Cummins lower alternator mount PN 3930820 Link ($36.04)
Cummins tensioner mount plate PN 3930838 Link ($51.48)
Cummins water inlet housing and compressor mount PN 3930888 Link ($247.17)
Cummins square-cut water inlet gasket PN 3906697 Link ($4.53)
Cummins Alternator brace Link ($38.73)
Thermostat Housing Gasket 3923331 Link ($9.85)
Rectangular ring seal Cummins PN 3906697 Link ($4.53)
Hex Flange Nut Cummins PN 3903210 Link ($3.91)
Hex Flange Cap Scew Cummins PN 3902460 Link ($5.95)
Hex Flange Cap Scew Cummins PN 3089016 Link ($7.41)
Hex Flange Cap Scew Cummins PN 3903105 Link ($21.10)
Hex Flange Cap Scew Cummins PN 3052061 Link ($4.53)
Hex Flange Cap Scew Cummins PN 3900631 (2) Link ($5.18)
Hex Flange Cap Scew Cummins PN 3910495 (3) Link ($23.91)
Hex Flange Cap Scew Cummins PN 3900679 (3) Link ($15.36)
DCS Vertical Water Neck Assembly Link ($145.00)
89-93 Cummins 180° Thermostat Kit 3802968 Link ($41.93)
Cummins Belt Tensioner 3912254 Link ($120.00)
Dorman 34229 Air Conditioning Bypass Pulley Link ($41.55)
Bosch AL9960LH New Alternator 160AMP Link ($208.94)
New 8 Groove Diesel Truck Alternator Belt Pulley Link ($19.99)

Fuel
94-98 Dodge 5.9L 12 Valve Cummins Adjustable Overflow Valve Link ($42.25)
89-02 Dodge 5.9L Cummins Fleetguard LF3894 Stratapore Oil Filter Link ($12.99)
MicroGard Oil Filter Part #MGL57620 O'Reillys ($5.99)
94-98 Dodge 5.9L 12V Cummins 14MM Banjo Bolt Fuel Pressure Gauge Snubber Link ($21.14)
Cummins Injector Dust Sealing O-rings 3909356 Link ($10.80)
Bosch P7100 Delivery Valve O-rings Link ($36.00)
Cummins Injection Pump Gear Nut 3920921 Link ($18.51)
Cummins Injection Pump Gear Lock Washer 3920922 Link ($6.99)
Cummins Vacuum Pump Reseal Kit Link ($19.00)
LarryB's P-Pump Fuel Solenoid Wiring Harness Link ($62.95)
LarryB's Fuel Solenoid Diode for Dodge Cummins Link ($26.95)
1996 Dodge 5.9 12 valve Cummins Diesel Fuel Filter Link ($140.00)
Alliant AP4988747 Fuel Transfer Pump Kit Link ($93.16)
Gates Diesel only fuel fill cap Link ($4.15)
PLATINUM PRO FTK010188 31gal Diesel Tank Link ($83.89)
SPECTRA PREMIUM/COOLING DEPOT FG12J Sending unit Link ($58.79)
S.U.R.&R. Deluxe Fuel Line Replacement Kits KP1500 Link ($294.97)
Cummins Throttle Return Spring -Inner Link ($32.49)
Cummins Throttle Return Spring -Outer Link ($9.99)
LarryB's Feed Line/Fuel Heater/Filter Eliminator Kit Link ($46.95)
94-98 Dodge 5.9L 12V Cummins Fuel Pre-heater/Strainer Service Kit 3845400S Link ($7.00)
Cummins Fleetguard In-line Fuel Filter FF5079 Link ($7.20)
Brass Fuel Hose Fitting 3/8NPT x 3/8Fuel DOR 02960BP O'Reillys (x2) ($7.98)
Cummins 20mm Fuel Filter Stud PN 3926481 Link ($9.99)
Cummins Fleetguard Fuel/Water Separator FS19608 Link ($13.15)
5.9L 12 Valve Injector Return Line Banjo Sealing Washers 2x 3918188 Link ($16.00)
Cummins 12MM Banjo Seal Washers (6) X2 Part number: BS12MM Link ($14.16)
Cummins 14MM Banjo Seal Washers (6) X2 Part number: BS14MM Link ($14.16)
Dodge Cummins/DCEC 12 valve 3936316 / 4988747 fuel lift Pump Link ($75.00)
Continental Belts and Hoses 59211 3ft 1.75 Link ($34.97)

Tools
Engine Barring Tool Link ($34.95)

Exhaust
V-Band Clamp - Exhaust Downpipe to Turbo Link ($32.95)
Cummins Exhaust Manifold Gasket Package Link ($45.69)
Heat Shield Products Lava Wrap Link ($60.42)
Heat Shield Products Thermal Ties Link ($15.57)
94-98 Dodge 5.9L Cummins Exhaust Manifold Bolt Set Link ($43.00)
Diamond Eye 4" Aluminized Turbo Back Exhaust Link ($266.07)
Oil Drain Hose for Turbo 7/8" - Foot Link ($15.00)
Diamond Eye Straight Exhaust Tubing 400024 Link ($27.40)
Summit Racing® Muffler Clamps SUM-G4640-1 x3 Link ($14.91)
Exhaust Band Clamp, Lap Joint, 4.000 in. Diameter Link ($13.86)
AP Exhaust Hangers 339816S x4 Link ($15.88)

Cooling

Heater Hose Elbow Gates 20338 O'Reilly ($8.99)
Summit Racing SUM-294021 - Summit Racing® Heater Hose Link ($29.94)
Painless Performance 30111 - Painless Performance Temperature Sending Unit Link ($47.99)
Gates Upper Radiator Hose Part #22081 O'Reillys ($26.99)
Gates Lower Radiator Hose Part #22082 O'Reillys ($19.99)
Gates Bypass Hose Part # 20357 O'Reillys ($7.99)
Summit Racing® Coolant Hose Connectors SUM-380602 Link ($4.97)

Air/Intake
Cummins Large Intake Gasket 3938152 Link ($16.97)
Cummins Vulcan Intercooler Hose/Clamp Kit Link ($189.99)
Isolator Right, Upper Radiator Cooler Mounting PN 52027827 Link ($28.80)
Donaldson BHAF Replacement High Flow Air Filter Link ($34.96)
Cummins Alliant Intake Grid Heater Gasket Link ($11.88)
Cummins Adjustable Boost Elbow Link ($19.90)
AFE Power Air Filter Wraps and Prefilters Link ($27.55)
Squirrelly 4.0" to 4 inch 90 Degree Elbow Silicone Coupler Black Link ($24.99)
Spectre Performance 9709 4" Straight Aluminum Intake Tube Link ($11.40)
HPS (SSTC-108-116) 108mm - 116mm Stainless Steel T-Bolt Clamp for 4" Hose Link ($22.80)

Timing
Cummins 5.9L 1994-1998 Killer Dowel Pin (KDP) Repair Kit Link ($65.95)
Felpro Timing Cover Gasket Link ($35.99)
Dodge 5.9 Cummins Front Crankshaft Seal and Timing cover gasket Link ($45.00)

Gasket/Etc
Dodge Cummins Magnetic Oil Drain Plug Link ($12.00)
Dodge 5.9 Cummins 3934486 Rear Main Seal & 4947667 Cover Gasket Link ($35.00)
Fel-Pro Replacment Oil pan gasket Link ($16.01)
Edelmann 7918 Power Steering Pump Seal Kit Link ($8.23)
Cummins Valve Cover Bolt Link (4) ($22.40)
Cummins Valve Cover Grommet Link (4) ($7.00)
1989-2017 Dodge 5.9L/6.7L Cummins Diesel Phillips Block Heater Cord Link ($19.00)
Gates Century Series Micro-V Serpentine Belt Part #K080670 O'Reillys ($51.99)

Case Vent
Cummins Diesel Tappet Cover Gasket 3284623 Link ($22.41)
Cummins OEM Replacement Tappet Cover 3990732 Link ($138.68)
Cummins Valve Cover Bolt Link (4) ($22.40)
Cummins Valve Cover Grommet Link (4) ($7.00)
Case vent valve cover Link ($90.30)
Case IH O-Ring PN 500315795 Link ($5.61)
Case vent breather Link ($20.14)
Cummins OEM Replacement Tappet Cover 3990732 Link ($138.68)
Mann Provent 200 Link ($139.42)

Other
Cummins Paint (Primer, Black, and Beige) Link ($87.51)
Cummins OEM Black Paint - 12oz Can Link ($12.36)
Lokar Tremec Shifter Boots 70-BFS Link ($15.97)
1986 GMC C60 Instrument Cluster No Tachometer Ebay ($113.96)

Wiring

Waterproof Universal Off Road Fuse and Relay Power Distribution Center Link ($115.00)
Ultima Select Starter New Part # N712652A Link ($195.99)
Super Start Premium Top Post Battery Part #27PRM Link ($257.98)

Other
Dodge transmission clutch fork pivot ball PN 52087542 ($25.00)
National Bearing Clutch Release Bearing Part # 614114 Link ($46.99)
MasterPro - Remanufactured Power Steering Gear Part #503-0119 Link ($157.99)
 
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mckustomfab said:
Are you planning on running fuel lines? I am going to run mine down the driver frame rail to keep it away from the exhaust heat and that's the side the lift pump is on anyway.
Click to expand...
New fuel lines are pretty much required imo. Run em inside the driver rail.
 
Didn't get too much done today but was able to get my timing on the injection pump bumped up 3 degrees from 12.5° to 15.5° I used a home made timing tool, I got the idea from one of the Dodge forums but I don't remember which one. I used a pressure washer fitting that has the same thread as the delivery valve. The fitting was a 22m to 3/8, I cut the 3/8 side off flush with the wrench lug and tapped a hole for a thumb screw. Then I bought a dial gage from harbor freight, I also bought a barring tool to turn the engine over and the delivery valve socket.

Fitting
Gauge

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I also got my front gear cover bolted up, and sanded all of the paint off of my injecton lines so I can paint them. Hoping to get everything bolted up tomorrow, add some fresh oil and hook up fuel and maybe try to fire it up.
 
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Here is a few more pics from this weekend, I was able to get most everything bolted on to the engine. I still need to put on the new oil pan, turbo oil drain hose, and fuel filter, small things like that. Im hoping this weekend I can get it test fired so I can get started with the install...

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When I do the install I plan on cleaning up the frame rail and fire wall, not sure if I am going to go through the trouble of painting the frame or not because my rails are fairly clean, the ones in the photos are of my "engine cart". If I paint them will kind of depend on how the swap goes, i'm trying to minimize the down time of my truck. Here is a pic of my cart without the engine in it.

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