My 88 crew cab dually 12v cummins/nv4500 swap. Update 12-23-13
 

I finally picked up a donor truck for my cummins swap for my 88 crew cab and got the motor and trans pulled last weekend. While the motor and trans are at my buddies getting gone through with all new gaskets and seals I plan to start pulling the 454/400 combo from my 88. I have a few questions and if anyone has done this your help is much appreciated. I plan on buying a motor mount kit that will allow the cummins to bolt to my stock gm motor mounts and will build my own trans mount. My biggest question is should I use a stock clutch pedal assembly from a square body and then mount my dodge slave in the firewall and hook it to the gm pedals. I also plan to use the dodge radiator and intercooler with gm electric fans from a 06 chevy truck. My other big question is has anyone used the factory high mount a/c brackets from cummins powered ford f800 instead of notching the frame and if so did they run into any other problems. If anyone has any recommendations on how to make this go easier than I may be making it please let me know.

Now on to the pics

The truck that's getting the swap, this is a photoshop of it lowered
http://i1237.photobucket.com/albums/...s/17e180e1.jpg
http://i1237.photobucket.com/albums/...s/d1acadf1.jpg
The donor truck coming apart
http://i1237.photobucket.com/albums/...33B32E3385.jpg
http://i1237.photobucket.com/albums/...33AB19D429.jpg
http://i1237.photobucket.com/albums/...33A39AF263.jpg
And it's out
http://i1237.photobucket.com/albums/...33B85B2756.jpg
And after a ton of degreaser and power washing
http://i1237.photobucket.com/albums/...33BD663D3A.jpg
http://i1237.photobucket.com/albums/...33C2841558.jpg
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Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

That engine did not come in that Dodge originally, That is a VE pumped 12valve out a non-Chrysler product (Bus maybe). That truck is suppose to have a P7100 pumped 12 valve.

Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

I'm in the process of doing this swap.
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Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

Ya I know the motors not the original for the truck because it has a cummins recon tag on it. I'm ok with the ve pump since it starts easier and gets better fuel mileage. I'm not looking to be pulling loaded 40 ft trailers so the power difference is ok with me.
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Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

You might wanna look around on http://www.4btswaps.com/forum/forum.php don't let the name fool you its pretty much a diesel swap in anything.For swap parts http://www.tndieselpower.com/site/products-page/ and http://www.autoworldmt.com/Page_11.html have most of everything you could want or need.

Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

Got to start back on my project today and made some good progress. Got the truck fired up and in the shop and started killing the wasp and their nest.
http://i1237.photobucket.com/albums/...0106819BE7.jpg
Then started pulling the front clip a piece at a time.
http://i1237.photobucket.com/albums/...010F1ECD1B.jpg
http://i1237.photobucket.com/albums/...01144716B4.jpg
Got all the nose off then went to getting the motor/trans ready to come out.
http://i1237.photobucket.com/albums/...01190C8F24.jpg
http://i1237.photobucket.com/albums/...011E5CFB39.jpg
Finally got it all out and apart.
http://i1237.photobucket.com/albums/...0124AF081D.jpg
http://i1237.photobucket.com/albums/...012D2FA74A.jpg
http://i1237.photobucket.com/albums/...0138D4A001.jpg
then spent over an hour degreasing the frame and front suspension. I didn't take any close up before pics but I'm betting the truck weighs about 10 pounds less after cleaning.
http://i1237.photobucket.com/albums/...01491D3E78.jpg
http://i1237.photobucket.com/albums/...0152AB2402.jpg
http://i1237.photobucket.com/albums/...0157421E39.jpg
More to come tomorrow
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Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

this swap is in store for my truck as well as a 4x4 conversion, but i sitll havent decided whether or not to used a built 4l80e behind the cummins (because i already have it!)

Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

A good built 4l80 is hard to beat especially if your trucks an auto. Mine is an auto originally but I can't resist putting the nv4500 in it
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Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

Wow this looks like it will be a sweet conversion BlackSheep. Looking forward to your progress....

Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

Im along for the ride as this is in my plans for the future!

Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

What did you pay for that donor truck?

Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

I traded a 99 Tahoe I had around $3500 in straight across for the donor truck.
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Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

I used the stock Chevy pedal assy. with a 1998 Dodge master & slave set.
The Dodge master mounting surface or "flange" sits at an angle as opposed to the mounting location on the Chevy firewall which is vertical, simple fix for that as well as attaching to the pedal. I'am working 3rd shift so give me a couple of days, it will be my day off and I'll take a few pics, be easier to grasp. Me flapping my lips after being up all night aint gonna help much.
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Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

Well I got the motor and trans stabbed today along with the floor cut out and ready to fit the older bolt in high hump. In the pics the hump is slid back because I've got the rand jacked up to high while I was working on the new trans crossmember.
http://i1237.photobucket.com/albums/...579F81E65F.jpg
http://i1237.photobucket.com/albums/...57A503888E.jpg
http://i1237.photobucket.com/albums/...57AAE001F5.jpg
http://i1237.photobucket.com/albums/...57AF913E2C.jpg
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Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

Tomorrow I hope to get the trans crossmember finished and all the clutch pedal and hydrolics buttoned up.

Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

That's gonna be a sweet ride!

Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

Since I didn't update yesterday here is the progress from yesterday.

Got the column pulled and cut the auto shifter off the filled the hole with some foam sat in then covered in 3n panel bond to fill the hole. Got is all sanded and in primer but forgot to snap a pic.
http://i1237.photobucket.com/albums/...0737A910BB.jpg
Then I started installing the clutch pedal. I had to trim off a chunck of the brace so the pedal could have room for full movement
http://i1237.photobucket.com/albums/...073E1D7875.jpg
Then I made a template of the clutch pedal and used it to resize the auto brake pedal
http://i1237.photobucket.com/albums/...07471A9BD9.jpg
Then I got a 7/16 bolt 8" long and put it through the brake and clutch pedal pivots using washers as a spacer to get the clutch pedal over where I wanted it. Then added a firewall brace after the clutch pedal was slid on
http://i1237.photobucket.com/albums/...074E855761.jpg
Then I built a heavy duty plate to lock and hold the dodge master cyl in the firewall.
http://i1237.photobucket.com/albums/...0755601AB3.jpg
http://i1237.photobucket.com/albums/...075B5669AA.jpg
Then sprayed some black paint on it and drilled some holes in the firewall and mounted it
http://i1237.photobucket.com/albums/...076175E623.jpg
Then using the chevy and dodge rods I lengthened the rod and locked the master cyl in the firewall and attached the rod to the clutch pedal
http://i1237.photobucket.com/albums/...076E788490.jpg
http://i1237.photobucket.com/albums/...077C51E25A.jpg
http://i1237.photobucket.com/albums/...0782BBC27F.jpg
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Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

Today I started fitting the dodge radiator, inter cooler, and a/c condenser in the 91 suburban core support. I had to cut the boxing braces that go up both sides of the core support where the core support bolts drop through off to fit this big inter cooler in. Then I cut the lower braces off the dodge core support and welded them to the bottom of the core support so the rubber grommets that are on the bottom of the inter cooler to sit in.
http://i1237.photobucket.com/albums/...0787E12C84.jpg
Then I welded some nuts in the top and used some old braces to bolt the top of the inter cooler in
http://i1237.photobucket.com/albums/...078D3ED16C.jpg
Then I did the same thing to hold the rubbers on the bottom of the radiator to the core support as I did the inter cooler and then welded some nuts flush in the top of the core support to bolt the top of the radiator in.
http://i1237.photobucket.com/albums/...0792584122.jpg
http://i1237.photobucket.com/albums/...07984D21D4.jpg
Then I started fabbing up the a/c condenser by just welding on some brackets and cutting two holes for the lines to go through. I had to bend the bottom line in so it would go through because it used to go straight up. I'm just using this condenser for mock up, I'll be putting a new one in when done
http://i1237.photobucket.com/albums/...07A71ACB46.jpg
http://i1237.photobucket.com/albums/...07AC8452E3.jpg
A pic of where the lines come through the core support
http://i1237.photobucket.com/albums/...07A2653A10.jpg
Also got my trans crossmember back today from the metal shop that I had bend it up. Got it in and they made the z brackets that tie in the top of the frame 1.5" to short so I'm either going to have to weld a tube across that I can bolt them too
http://i1237.photobucket.com/albums/...079D7B5344.jpg
And a pic of the 4" exhaust that the dealership my brother works for took off a 08 chevy diesel that they sold me for a grand total of $20
http://i1237.photobucket.com/albums/...07B54E0D13.jpg
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Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

Got some more work done today. Had some 1.5" square tube cut and welded in the trans crossmember and the holes drilled to tie it all together
http://i1237.photobucket.com/albums/...8D6BCDCA6B.jpg
Then I mounted the core support and measured for fan clearance. It's very tight but I order 2 12" slimline fans that will have plenty of room
http://i1237.photobucket.com/albums/...8D737EF5FA.jpg
Then I went to oriellys and got a factory frame mount fuel pump for a 96 chevy with a 6.5 diesel and mounted it were the fuel filter used to go on the frame
http://i1237.photobucket.com/albums/...8D80CD4A23.jpg
Then I pulled the motor and trans back out to swap in the new motor mounts and do a little frame work were I had to do some trimming but that will come tomorrow
http://i1237.photobucket.com/albums/...8D7896A4C2.jpg
http://i1237.photobucket.com/albums/...8D855B952E.jpg
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Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

Well over the weekend i got the rest of the fab work completed

I cut a 1/4 crescent shape out of the front crossmember and knocked it down as I welded it back together for some extra crank pulley clearance.
http://i1237.photobucket.com/albums/...8A8F5B76F5.jpg
Then I cut the front crossmember and pulled it foreword on the right side to give the a/c compressor pulley clearance and welded a plate back it the bottom
http://i1237.photobucket.com/albums/...8A9742994A.jpg
Then I plated the top of the right frame rail were I cut a notch out to clear the a/c compressor
http://i1237.photobucket.com/albums/...8A9CBE19E3.jpg
http://i1237.photobucket.com/albums/...8AA246FB93.jpg
Then I pulled the bed to change all the rubber fuel lines and remove the in tank pumps
http://i1237.photobucket.com/albums/...8AAE3DCFD5.jpg
http://i1237.photobucket.com/albums/...8AB9AFA537.jpg
I used some 3/8" metal line with compression fittings to run to the bottom of the tank and attached some socks on the bottom to filter
http://i1237.photobucket.com/albums/...8AA7491283.jpg
Then I got the motor and trans loaded up in the 71 and ready to go to my buddies shop for new gaskets and seals
http://i1237.photobucket.com/albums/...8AB492FABD.jpg
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Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

kewl project man. Really liken the 6bt. Ive got an 88 cc dually too. Oposite of yours, Mines White. I'm on the fence between a 5.3/6.0 swap or find a cummins to drop in..

Any new updates on your truck. Let me know how you like the cummins or if you don't like it.

Great job sofar,

David

Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

I definitely think ill like the cummins and I know I'll love the nv4500. I dropped the engine/trans off to get gone through and all dolled up today and I'm planning on ordering my 6/8 drop kit and steed speed header tomorrow.
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Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

you need two brace rods from your master cyl mount on the firewall to the pedal pivot point, or you WILL break the firewall out! the factory hydro clutch setup has them, and now you're running a much bigger setup.

Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

Very cool project,definatly following this one

Re: My 88 crew cab dually 12v cummins/nv4500 swap. If anyones done this please come i
 

Ya I plan on adding another on but ran out of time on my week of working on it. Was contemplating putting one from the pivot bolt back to the heavier metal dash support because its so tight under the dash at the firewall. You think that would add enough support.
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