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Second gen chevy to cummins power, how-to post

Need to know for what year of truck.

I make parts for the GM straight axle truck,ifs .
also do Ford parts as well.

Thanks
CrewCab59
 
lets say you have a 1989 TBI 350 th400 2wd crew cab and you want to upgrade to a 5.9 cummins with a manual and the motor and tranny are complete. what would the project look like $$ wise. (other then the motor and tranny price)
crossmembers?
mounts?
radiator?
go to big block coils or do air bags up front for the added weight?

any help will be greatly appreciated guys
 
55Willy said:
lets say you have a 1989 TBI 350 th400 2wd crew cab and you want to upgrade to a 5.9 cummins with a manual and the motor and tranny are complete. what would the project look like $$ wise. (other then the motor and tranny price)
crossmembers?
mounts?
radiator?
go to big block coils or do air bags up front for the added weight?

any help will be greatly appreciated guys
Click to expand...

No crossmember needed if it's a 2wd,Mounts $350.00,radiator a 2 core is all that's needed.
the rest is small stuff ,fuel lines,fuel tank cleaned and remove the pump,clutch pedals,wiring,exhaust,air filter ,drive shaft work.Labor it takes around 80-120 hours,depends on what you want it to look like,I charge $65.00 per hour to do a conversion.
Then you have the engine and trans,what clutch you install and engine mods that you want.

CrewCab59
 
what about gauge capatibility?
and I'd be doing the work myself with 2 friends. (so labor is pizza and beer)
I have a hydro clutch set up for a chevy but i thought dodge used a cable??
I'd want to do all the engine mods prior to putting it in along with a very good strong clutch.

just an intercooled 12 vavle is all i need.
 
55Willy said:
what about gauge capatibility?
and I'd be doing the work myself with 2 friends. (so labor is pizza and beer)
I have a hydro clutch set up for a chevy but i thought dodge used a cable??
I'd want to do all the engine mods prior to putting it in along with a very good strong clutch.

just an intercooled 12 vavle is all i need.
Click to expand...

Gauges,You'll need EGT,Boost !
Hyd clutch pedals ,Dodge uses a hyd slave outside the bellhousing.
1.Gm slave and master won't push anymore than a gm clutch ,to be able to hold the power of the Cummins and the upgraded power plus a bigger cluch you'll need to use a (Ford master 87-92 ) and a (dodge slave 94-98.5 ) they both use the same line and fittings.
The clutch I used and sell are South bend clutch 13 1- 1/4 con ofe.

A 12 valve 91.5 to 98.5 will work they are all intercooled, 91.5-93 were Ve pump,94-98.5 are P-7100 pump.
 
I'v seen a bunch of the swaps using the SBC clutch so thats what I think I'm gonna go with. Also since you've done a few of these should I limit myself to a 12 valve or is the power gains of a newer motor worth the extra coinage?

also do you have pics of your motor mounts?
 
55Willy,

The SBC is the way to go,and that what I use in all my conversions .The 12 valve will be the cheapest and less problems to deal with as well,unlike the newer engines.The only way it would be a better choice is if you got the engine for Super Cheap.

I have pics of my mounts in this section ,unless you need somthing else that I don't show.

CrewCab59
 
CrewCab59 said:
55Willy,

The SBC is the way to go,and that what I use in all my conversions .The 12 valve will be the cheapest and less problems to deal with as well,unlike the newer engines.The only way it would be a better choice is if you got the engine for Super Cheap.

I have pics of my mounts in this section ,unless you need somthing else that I don't show.

CrewCab59
Click to expand...


I have a set of these mounts and a Crossmember very nicely done .

I have changed direction on my project about a 100 times now the Plan is to stick a Modded 325 Common Rail In a 91 V3500
 
CrewCab59

Just picked up a '92 W250 86K mi with the 5.9 CTD, A618 (47RH), and NP205 for my '86 K3500 (we spoke on the phone a couple days ago). I'll be wanting to get started on it once the snow starts melting around here.

Few questions..

Any reason not to use the original Dodge radiator? Picking up a GM 2 row is obviously not a big expense just curious. I'm sure I could find someone willing to trade me a new 2 row for a close to new 4 row anyhow.

What air filter are you running? I don't think I would have room for the air box thats in the Cummins. I saw your pics and it looks like you're running a big ass K&N or something off the factory air tube?

What did you do about the radiator overflow tank? Should I use another, say the dodge one or something?

I was thinking about modifying the Dodge driver side double battery tray to fit my truck. Any thoughts? I'd have to come up with a plan for the windshield washer tank if I go to the DS with the batteries. It's required for inspection here.

Do I have to cut the inner fenders to clear the intercooler/turbo stuff on the passenger side? How about the A/C accumulator?

Any recommendations on the transmission linkage? Planning on running that A618 in place of the original TH400. Also, what do i need to scavenge from the W250 to control that tranny.

Transmission cross member? Run the Dodge member unit I would guess?

Do I need to box my frame in or anything for strength? I know the GM's are fairly weak around the rear shackles in the front?

I'll be in touch shortly for the motor mounts.

Edit: One more thing. The donor is rusty and the pan is leaking. Is that something you could locate for reasonable $$?

Thanks again,

Mike
 
pseudomike said:
CrewCab59

Just picked up a '92 W250 86K mi with the 5.9 CTD, A618 (47RH), and NP205 for my '86 K3500 (we spoke on the phone a couple days ago). I'll be wanting to get started on it once the snow starts melting around here.

Few questions..

Any reason not to use the original Dodge radiator? Picking up a GM 2 row is obviously not a big expense just curious. I'm sure I could find someone willing to trade me a new 2 row for a close to new 4 row anyhow.

What air filter are you running? I don't think I would have room for the air box thats in the Cummins. I saw your pics and it looks like you're running a big ass K&N or something off the factory air tube?

What did you do about the radiator overflow tank? Should I use another, say the dodge one or something?

I was thinking about modifying the Dodge driver side double battery tray to fit my truck. Any thoughts? I'd have to come up with a plan for the windshield washer tank if I go to the DS with the batteries. It's required for inspection here.

Do I have to cut the inner fenders to clear the intercooler/turbo stuff on the passenger side? How about the A/C accumulator?

Any recommendations on the transmission linkage? Planning on running that A618 in place of the original TH400. Also, what do i need to scavenge from the W250 to control that tranny.

Transmission cross member? Run the Dodge member unit I would guess?

Do I need to box my frame in or anything for strength? I know the GM's are fairly weak around the rear shackles in the front?

I'll be in touch shortly for the motor mounts.

Edit: One more thing. The donor is rusty and the pan is leaking. Is that something you could locate for reasonable $$?

Thanks again,

Mike
Click to expand...


Mike ,

The GM bolts right in with stock clamps .
The air filter is a AFE and a stock 2nd gen air box elbow cut down .
Use the stock overflow .
Use the stock battery tray diesels have 2 trays with a washer tank .
The inner fenders are not touched !
The A/c acc not touched .

The 47rh wasn't used until 94 -96 only which has loc up and OD .You can control them with toggle switches or pressure switches .

Use your stock crossmember .
The frame is fine , no need to box unless you want to .
I would speed the extra cash and get a deep mag pan or other deep pan .

Scott
 
Scott:

Thank you for the info. Your are correct on the trans, A518 non-lockup.

I'll be in touch for the motor mounts shortly.

On the cross member, what should i use for a transmission mount. The Dodge has some funky setup under there. Perhaps it will fit my double hump? I guess i won't know for sure until I put her in place.

On the pan, I should have clarified but i meant the Cummins pan not the tranny unless you recommend a deep pan for the engine but I thought there were clearance issues even in stock form?

Thanks again,

Mike
 
pseudomike said:
Scott:

Thank you for the info. Your are correct on the trans, A518 non-lockup.

I'll be in touch for the motor mounts shortly.

On the cross member, what should i use for a transmission mount. The Dodge has some funky setup under there. Perhaps it will fit my double hump? I guess i won't know for sure until I put her in place.

On the pan, I should have clarified but i meant the Cummins pan not the tranny unless you recommend a deep pan for the engine but I thought there were clearance issues even in stock form?

Thanks again,

Mike
Click to expand...


Mike ,

I thought you were talking trans pan . The oil pan just keep the stock pan ,the Bus 5.9 do have a bigger pan .

Scott
 
Intercooler

I'm looking at mounting an intercooler in my truck. Doing a bit of research, I've found people using both Duramax and Cummins intercoolers. Which one should I start looking for? What mods have to be done?
 
Oh, forgot to mention. I've also seen some custom intercoolers too. This might be the way to go. Here's one from a guy that put a cummins in a 2wd suburban.

DSCN2276.jpg
 
we used the aftercooler from the the donor truck it worked well with the 73-80 clip I need to do a build thread I used crewcab5.9's mounts and crossmember quality stuff to be sure!!
 
CrewCab59
I’m planning on buying a M1009 here within the next 45 days off governmentliquidation.com and don’t care for the 6.2’s very much. I’m thinking about a 4BT to replace it with and picking up a M1008 for the axles. Those axles come with 4.56’s, which seem like they might be a bit low for the 4BT, any suggestions on gearing or has anyone else run this setup with the TH400? I’m thinking of going with 37” tires with this setup. I’m also planning on getting a doubler from ORD to put behind the TH400 for trail use.
How much HP can the 4BT put out? I’m not looking at racing anything but want some to turn 37” tires without any problems. I’ve only dealt with the 6BT’s and love them! But don’t see why I would need something that big in a Blazer that will be for playing on various terrain.
 
I think a reliable 300 hp could be obtained from a 4bt with the correct setup
I'd love to find a 4BT especially one of the newer ones I think they would be prefect in a 1/2 ton with a NV4500 3.73's and 35" tires you could probly get close to 25-27 MPG with that setup and have the power of a stock 454
 
I'm curious as to if the 4BT has the same engine mounts as a 6BT? I see that different people make these but it just says Cummins to Chevy conversion. I wouldn't want to buy one then find out its for the 6BT. As far as power goes, I'm not looking for anything over 200HP & 400lbs of TQ. I've been reading in another forum for 4BT builds and dyno numbers http://www.4btswaps.com/forum/showthread.php?t=757 to see what can be done. I think I'd be happy with about 150HP since I'm in a hurry to get somewhere!
 
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