Military Crew Cab Build-Cummins swap.

[Kay86K5]

@Kay86K5 knows about the hydraulics stuff I think.

I'm not as familiar with the dodge specific stuff but...@Cruz89K5, what year and make is your NV4500 again? When I converted my 89 V3500 from auto to manual, I just used an 89 GM master cylinder mounted on the firewall. Now, I'm using a 95 GM NV4500 on my swap. So I'm using the 95 GM bell housing and 95 external slave cylinder with the hydro line run all the way up to the square body master cylinder. Then I just adapted the two lines together (the 95 hydro line and the 89 line coming out of the master) with a $5 swaglok adapter fitting (similar to a compression fitting) and that was it.

Like I said though, I'm not sure the differences with the dodge NV4500 hydraulics though, so not sure if this is a possibility here.

 

[obijuank5]

The dodge slave needs to be run with the dodge clutch. Then you need a dodge stroke length master that fits the bolt pattern for gm.
Scott at tn diesel already figured it out and it works well. I don't know what the master application is though

 

[Cruz89K5]

Thanks for all the input. The trans is a dodge, 98-00 I believe. So I'll need a dodge slave.

I saw Tennesee Diesel Performance's setup. As always, I was hoping to save a little money, but it does look like the easiest solution from the reading I have done.

Mounts arrived today. Also a picture of the trans. Purple drivetrain accents has become the tradition around here. Havent made any progress in the shop other than a little degreasing and paint.

 

[454Sub]

I knew plum would catch on eventually.

 

[Justin V]

I knew plum would catch on eventually.

You shut your dirty mouth!

 

[Cruz89K5]

What are you guys doing for gauges? I'm thinking about ISSPRO because they have a tach available. I missed a steal of a deal on OEM diesel tachs on ebay a while back too... Pyro, boost, and RPM in a pillar. I've seen the pillar pod from 73-87 trucks, but I dont have pillar trim. I was thinking about tacking some 90 degree brackets in place to mount one to. I was curious as to how well it would hug the pillar without trim. Any suggestions?

Parts are rolling in, so I'm going to have to start making some progress soon. I'm running out of room in the house and the ol lady is getting tired of the crossmember in the floor.

I knew plum would catch on eventually.

Been painting them metalcast purple since 06.

 

[454Sub]

Lol.

I been using Ace Hardware Plum since 06. I love it.

 

[83ChevyK5Blazer]

 

[Cruz89K5]

Everything I ordered has finally arrived, so i spent some time in the shop last night. I still need to order the clutch hydraulics from tndc.
As usual, my ORD order was incomplete. The second half drop shipped from advance adapters. The 29 spline 205 input ord sells is from advance. It is a very good looking piece of hardware.

Last night I got the governor springs changed out, the kdp tabbed, repair sleeve on the crank snout, and resealed that nightmare that was the oil cooler. It may be common knowledge, but cpp had a neat little cummins part pin retainer that was 3 bucks. Since I had a bunch of gaskets coming from them I picked it up. Talk about a time saver.

I'm going to try to get the pump off this weekend and reseal the tappet cover. I plan to advance the timing a bit when I put it back together. That's all the progress I've made this week.

 

[Cruz89K5]

Life kind of got in the way of this, but I've been making some time recently for it. I bought a newer Cummins Ram in May, and I'm already tired of the payment. I also bought a trackhoe to start a side business. I sold my CTSV and I'm selling the newer truck so I can get the side business going. So I'm going to go back to this with the intention of it being my daily driver and retiring my 07 Cummins truck to trailer only duty. I havent taken many pictures along the way, but here's a few.

I pulled the pistons to check the rings. Rings looked good. Noticed the wear on the bearings. Bought new bearings and rings. Ran a deglazing hone down the cylinders and put it all back together. The main bearings looked fine.


I stabbed the motor for the first time Saturday. I've still got the cut the rest of the factory cross member out and get the swap crossmember in. I'm also going to have to trim a bit around the forward most crossmember for the balancer. Firewall clearance seems pretty good right now. I've still got to order the hydraulics for the clutch and finish notching the rear of the transmission housing to get the shifter to clear, then worry about shoving it all back in there. I'm also going to advance the timing a bit and buy a small upgrade injector and fuel plate for it. The plan for now is to try to run a first gen fan hub with the second gen clutch and fan. I have more room than I thought I would have, so hopefully it will fit, I'd rather have a mechanical fan as I intend to use the truck to tow often. That's all for now. I should have the engine back out this week so I can get to work on the truck side of things.

 

[Cruz89K5]

I've slowly been plugging away at this this week. I manage to get the tailhousing clearanced for the 205 rails, removed the rear oil seal, and married the two for the first time. Resealed the case and cleaned most of the crud off of it and painted it. I have the core support hacked and everything fits, barely. I wanted to use the dodge condenser but there isn't room. I'm going to have to trim a bit for the intercooler on its own. Looks like a GM condenser will fit still.

Tennessee Diesel says the mounts will allow a stock fan with a 2 row radiator. I have a 2 row in my old K5, but I'm skeptical. I dont want to run electric fans if I can squeeze a mechanical fan in there. I plan to change all the front sheetmetal in the future, the upper part of my core support is damaged, and the fronts on my fenders are as well, so I didnt really try to make the cuts look good. I've got poly motor mounts on the way, and an injector install kit. I had planned to buy upgraded injectors, but I'm running out of money, so the stock ones will go back in for now so I can spend that money on clutch hydraulics.

When the mounts come in I'll pull the motor, get the new engine crossmember in, swap the mounts and clearance the front crossmember, I intend to bolt the trans up and stab them as an assembly. Should be easy with the trackhoe.

 

[Cruz89K5]

It's running. I bought a dually bed and got a great deal on 5 37s that matched 2 I already had. 2" spacer wasnt enough, so I've got a 3 on order. The trucks starting on the key and charging. I left the ac compressor off for now, going to find a high mount town the road. I've driven it a bit around the neighborhood. I changed to a hydroboost pump and of course The power steering pump is leaking its ass off, so I have to figure it out. I still need to get the tank dropped and run fuel lines, but I'm progressing slowly. Pictures in no order.

 

[stockk5]

I was looking through the thread, what is your lift on this? Looks great

 

[Cruz89K5]

I was looking through the thread, what is your lift on this? Looks great

Thanks, I'm really happy with how it sits. It's all spring and I bought it second hand. It was advertised as 8". If I recall correctly I measured about 7" lift over the stock springs. I had to trim a bit of the front fender lip on the rear side to clear 37s .

 

[LLeff]

truck looks great, i must say that syclone makes me jealous

 

[Cruz89K5]

I've got about 1500 miles on this so far. Only one issue with the negative terminal pulling free and keeping the alternator excited. Made for some really bright headlights. The weight has taken its toll on the used leaf spring bushings, they're on the list to replace.

My front driveshaft was too short, and the one in the GMC is too long, so I'm going to have the gmcs shaft shortened for the crew cab. I need to bend the 205 shifter a tiny bit to clear the seat a little better.

Fuel mileage has been unbelievable. In town 15mpg. 67-75mph highway the truck gets 20mpg. I've verified the distance with the GPS and ran it several times to verify. 19-21 has been the average. I hesitated to post this. As I never believe the cummins guys with their 30mpg claims. My 6.7 truck averages 13-15.

Engine is still stock (160hp), plate slid forward and 4k springs. Power is better than the 454 was. I still plan to add some power as soon as I can afford it.

 

[Truckman4life]

So in those pics they are 37/12.50 tires on factory dually wheels and a 2" spacer or do you have the 3" spacer on? If I end up swapping my dually to 4x4 I'm debating on keeping it a dually or swapping to single rear wheel.

 

[max 02]

I`d be happy with your mileage. Our LB7 Duramax`s get around 18-20 and my daughters 24 valve is about the same. All of them on 33`s

Your rig look`s mean! I like it!

@Truckman4life keep it a dually.

 

[Cruz89K5]

So in those pics they are 37/12.50 tires on factory dually wheels and a 2" spacer or do you have the 3" spacer on? If I end up swapping my dually to 4x4 I'm debating on keeping it a dually or swapping to single rear wheel.

Yes they're factory dually wheels and 37x12.5s. I tried a 2" spacer and the tires were too close. I have a 3" spacer in there but I've talked to a few guys with the same setup and they have a 2.5" spacer. The truck is 103" wide with the 3" spacer.

 

[Cruz89K5]

I`d be happy with your mileage. Our LB7 Duramax`s get around 18-20 and my daughters 24 valve is about the same. All of them on 33`s

Your rig look`s mean! I like it!

@Truckman4life keep it a dually.

My hope was 15 highway. Obviously you dont build a brick shaped 1 ton dually on 37s for fuel mileage, but it's been a nice side effect. I've gotten asked the mileage at the pump a few times and it's pretty satisfying to give a number that isnt 5 like I used to.