87 Crew Cab 454/TH400 to Cummins/NV4500

[jltait]

Then I started to test fit the Cummins.

[jltait]

About this time I confirmed an issue I previously suspected. Since this was an automatic 2wd truck Cab the manual transmission was not going to fit without either a raised transmission hump in the cab or body lift. I opted for a 2" body lift which gave me the amount of room I needed. Since I am so stubborn I opted to fabricate it, I picked up a stick of 3 1/2" diameter UHMW (Ultra-high-molecular-weight polyethylene) and had it cut into 2" biscuits. I then drilled them on a drill press and allocated the correct hardware. I had about $75 dollars in the body lift. I like that my biscuits are 3 1/2" in diameter, the ones in the kits are usually 2" or so. Afterward I did find that Performance Accessories make individual 3" pucks, this may have been a good option as it took me a lot of time to do fabricate. I do not have pictures of the body lift install at this time but I certainly could put it up on the lift and snap a few when I get a chance if someone is interested.

[jltait]

Okay, once the body lift was in it was time to continue moving forward with fitment and mounts. I mimicked the drive line angle of the 454/th400 very closely. I was also able to find a mounting location that eliminate the need for drive shaft modifications. The NV4500 output yoke was moved rearward slightly compared to the TH400, but I was able to compensate by moving the carrier bearing rearward slightly ( the hose are slightly slotted). The original cross member was also re-used by cutting clearance in it for the larger NV4500 tail housing. I was able to bolt it through the original hole by rotating the rubber transmission mount (that came with the NV4500) 180* The stud is offset front to rear slightly and this compensated for the difference almost perfectly. Unfortunately I did not get photos of these aspect but when I get a chance I can put it up on my lift and get pictures of this.

[jltait]

So once everything was test fit with the transmission cross member and drive shaft in place I started fabricating motor mounts. I picked up 1/4 plate steel and a Lennox steel cutting blade for my circular saw. I came up with a design and CAD'd it up at work during breaks and lunches. I have access to CAD software at work. The first design centered around hanging the mount off the inside of the frame rail. after cutting one piece I decided to go back to the drawing board (err computer) and CAD'd up a second design that sat on the engine cross member ( not an option for 4x4's without replacing the crossmember). I have some pictures but none after they were deburred/welded/polished of surface rust/painted. Again I can get those and add them later but here are the pieces after cutting, then mocked up before deburring/welding.

[jltait]

Last update for tonight,
JLT

[suxtobu65]

Any updates sir?

[spgill2000]

What happened to this project?! Did it get finished?
Posted via Mobile Device

[spgill2000]

Hello? Project fail...

[Bowtie_luvr]

No project was not a fail. I had issues with my id/pwd here, family issues with my Dad's health and it came down to crunch time. I needed the truck, so I finished it (functional, never really finished) without any updated here. I was never able to get my profile here functional again, so I opened a new profile. I have several thousand miles on her now since the conversion. Injector lines have been the only reliability issue, I replaced them all with new Cummins lines shortly after the conversion and all has been well since. I am currently adding a Western Unimount plow.