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Originally Posted by Chevy3+3
1. What is the difference in the 1st & 2nd Gen 12 valve Cummins engines?
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1st Gen 12 valve - same block but VE pump which maxes out at about 400 hp. They're also quieter.
2nd Gen 12 valve - P-pump which can support up to around 1200 hp. Expect to pay $1000 extra for this engine.
Quote:
Originally Posted by Chevy3+3
2. Which would be a better choice?
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Both are good choices. If you want to go over 400 hp for winning races or making high dyno numbers, you obviously would want to choose the 2nd Gen 12 valve. If you want low rpm pulling power, there is little differece between the 2 engines.
Quote:
Originally Posted by Chevy3+3
3. Which manual transmission would be the easiest to swap in. I would love a Manual tranny but would think a little more work would be required (clutch pedal, clutch master cylinder, etc.).
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Easiest manual transmission to swap would be one of the manual transmissions offered in the Dodge truck such as the Getrag, NV4500, NV5600 or G56. The manual transmission is very much worth the effort if you know how to shift. They're much better at putting the power down to the ground than an automatic. They also tend to be more reliable especially with a Cummins.
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Originally Posted by Chevy3+3
4. If I were to use an auto tranny what would be my best option with simplicity and dependability in mind.
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Unfortunately, automatic transmissions and dependability especially behind a Cummins don't go together. These engines eat automatic transmissions because of the power they create at low rpm's.
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Originally Posted by Chevy3+3
5. Are body lifts usually required for firewall or tranny clearance (depending on tranny)?
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No, not even on the NV5600. The NV5600 is a tight fit in my Suburban but it did fit in there without any body lifts.
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Originally Posted by Chevy3+3
6. Can I utilize my factory radiator support and radiator? Or are mods definitely necessary in this area?
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Yes, as long as you have a 4 core or 3 core radiator which I know were used on Chevy diesel pickups.
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Originally Posted by Chevy3+3
7. Are there any prefab or factory built mounts or crossmembers for these types of conversions?
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Yes, or you can make your own. You can also use the engine mounts from the Dodge truck.
That said, I encourage you to do the swap. I'm very happy with the swap on my Suburban and I use it at my daily driver because of this. With the gas engine, 14 mpg was typical but with the Cummins 26 mpg is more typical.