Thought you guys might like this we just finished this up this week.

94 Chevy Quad Cab Dually 3500

212k on truck, 12k on Chevy crate motor 6.5 crank broke...bye bye 6.5

SPECS:
-94 CTD, stock intercooler, dodge radaitor and manual fan clutch
-Chevy NV4500 already rebuilt
-Resealed Motor- Oil pan, timing cover, rear main
-Fix KDP
-Head Gasket ARP Head studs
-16 degree timing adjustment
-#4 TST fuel Plate
-3000 governor springs
-Southbend MU 13-1.25 Con OFE
-No body lift
-factory dodge cruise control wired in
-dynomatted entire truck for sound deadening
- A/C we haven't finished its wired but needs some bracketry
-Needs air filter housing built, black zip ties instead of yellow and one last minute red wire to hide

Chevy Gutted

Nice Setup, Any pics of the whole rig?

Dodge going under the knife

some test fitting she is tight

motor mounts tached in after testing fan, intercooler, rad clearence

it all seems to fit no body lift like the internet says you have to do, we built new tranny tunnel instead 2wd tow rig w/ a body lift not here. we did have to do away with the dual headlight to fit intercooler and got the work package single headlight style.

motor timed to 16, KDP pin fixed

turbo checked for runout, and cleaned

head pulled 90hp injectors installed, forest of head studs installed

made a slide hammer tool for the injectors, old 6.5 injector lines had the same injector nut. Injectors came out like butter.

motor reasembled

dynomat firewall

Fatmat interior, it was cheape rand there was alot of space to cover

New tranny tunnell

And put back together wired up shortened driveshaft she runs like a scalded dog

pre swap pic stacks are gone whole rig

Nice swap.
What did you end up doing with the grill, headlights and what not that you took off? Sucks that stuff had to go. I hate the way the single headlight setup looks.

what wa the ballpark $ for the swap? i have thought about doing the same thing for my worn out '87 chevy...

what wa the ballpark $ for the swap?...

X2

How much of a hassle was it as far as engine swaps go? How much time you got in it?

I have been asked this Q alot? but its kinda of hard to say. taking a 12 valve and dropping it into the chevy w/ motormounts is fairly easy. But we gutted the interior and dynometted for sound purposes older trucks just aren't quiet and if your going to spend the money for something like this its nice to not have to yell at your passengers, we pulled head/studded, did fuel plate timed, govenor springs, cleaned everything, painted, wired so that everything is factory all the lights and guages work, wait to start ect ect, made the a/c functional as well as cruise control. plus we did guage installs pyro/boost. And it is way clean every wire is heat shrunk and soldered, bundlled and label'd. if anyone did have to go back into the harness not likely but also nice for diagnostics all the wires are label'd inside the harness for quick identification. not doing a body lift adds time, and instead of doing an electric fan, being 1000 miles from home with a bad electric fan brings the suck, adds more detaill to where the motor is placed and 1/4 of inch starts to matter. labor on the swap would range from $5k- 10k depedning on the mods you want. we probably have a 100-120 hours in this one. we may be slow but the final product is really clean and comfortable, no sacrifice was made. ie i have a cummins now my truck is too loud, i have cummins now so i don't have a/c, i have cummins now so i don't have cruise. It has it all like it did form the factory. When people ask about the swap i usually tell them its not wrth it unless you have something to start with. this was a very nice tow rig it just needed a motor to do what it was already capable of doing, frame, brakes, rearend are up to the tax. We shall see if the NV4500 is up to the task otherwise a ZF-6 will be next on the list.

I say you put the valve cover plate back on. my $0.02 nice clean swap :smokin:

Nice looking truck and swap! This is the exact same swap I've been considering, except I'd like to do a SRW 4x4. I just need to find a CC chevy in good shape to start...

Good job, Chase. Glad to see you got it finished up.

It looks better in person. It's a very clean swap. I stopped in a few times during the build up (it was on the way in to my old job) and its definitly done right.

right on nice one. I'm in the midst of the same thing right now. '97 Chevy 3500 CC dually. '95 Dodge Donor truck. I'm useing a built 47RH 2wd and a Ford divorced 205 in it too. I loved my truck before. now I really love it. I didn't have to lose the dual headlights, but the CAC is very close.

http://i144.photobucket.com/albums/r193/demon_044/Trucks/Swap017.jpg
http://i144.photobucket.com/albums/r193/demon_044/Trucks/swap025.jpg

Are you going to run an electric fan, looks like you tucked the CAC behind the lights i had to pull it out even with the lights to allow enough room for the fan. I also heard if you use a 1st gen fan pulley bracket you gain and additional 1 inch or so of clearence, of course i had already mocked everything up after hearing this tidbit but that may have allowed the space to tuck the CAC behind the lights. I took as much out of the firewall as i could with out getting into the HVAC box. your truck looks pretty sweet enter the cummins and it will finally run sweet.

It looks sweet. I wish I could afford to do that with my GMC, but not until the work situation improves.

Where did you get the clear turn signals on the old truck? I haven't been able to find any for mine.

CAC is slightly tapered back to clear the light casing. I'm ok with it. I've got 2 16" electrics that will go on the front as pushers. as its tilted back i have room on the front.

not to high jack your thread. but here it is just before the 6bt swap with the 22" alcoas, no lift.

http://i144.photobucket.com/albums/r193/demon_044/Trucks/Alcoa22mounted013.jpg

as it sits now. with the new fenders and cowl hood. can't wait to get it done.

http://i144.photobucket.com/albums/r193/demon_044/Trucks/swap026.jpg

that is pretty slick for an older one ton. what width are the tires? they appear to stick out a pretty good bit in the rear from under the fender, maybe its just the pic. Did you use a wheel spacer to fit them?

Dan at BTF has the spike lug nuts on his truck in black and they look cool as hell with black wheels and a black truck..

A friend and I stuck a 5.9 in a 77' chevy crew cab 2WD. No way we could install that motor and keep the A/C in the stock location on the 5.9 block, at least with the engine mounted center line in the frame. We did keep the firewall in with just a few minor BFH adjustments. We had that engine in and out about a dozen times using a tractor with front lift.

Your swap looks really good, nice work.

so question i know of a few gm's with nv4500's what did you do to mate it to a cummins?

dodge had factory nv4500 behind cummins from '91.5 through 2000-ish till the nv5600 took over. virtually same tranny except different input shaft and bellhousing for the obvious part. depending on the year of GM there were lower 1st gear ratios. and gms had a vibration dampner on the output shaft (@ the OD nut) so there were no 5th gear nut failures on GM nv4500s as far as I know. the outputs are different too. dodge is a 1 1/2" 29 spline. Gm is 1 1/4" 32 spline. same round 6bolt tcase mount though.

edit to clarify.....I'm not talking about the 4500 & 5600 I'm talking about the differences between the Gm 4500 andthe dodge 4500

The NV5600 was an option in 1999 on the Dodge, but only if you knew which code to ask for. Both the NV4500 and the NV5600 were available for at least a couple of years.

From what I understand, the NV5600 is a much heavier transmission than the NV4500. In Dodges, top & bottom gears are the same between them, but 3rd-4th in the NV4500 is broken up into 3rd-4th-5th in the NV5600.

Did you use someones motor mounts, or did you build your own? Currently i plan to build my own so i can put the motor where i want it. But if someone makes the mounts, and they put the motor in the best possible location, i'll buy them. Thanks in Advance, Josh.

Looks nice. I told a friend about this thread. He is putting a first gen in a 93 CC Dually 2wd. His is a GMC but basically the same. Also curious on the motor mounts and AC part. He is wanting to keep his stock AC because it blows icecicles now and he doesn't want to crack it.

you need to highmount the AC compressor. no questions. it cant stay in the stock location. you can use the Kenworth bracket that highmounts the Ac comp above the alternator. its a stock cummins part, used in the smaller T300 and such Kenworth trucks that got a 5.9 cummins. i got motor mounts from Tennessee Diesel conversions. but theres a few different places you can get them. no body lift. no firewall interference.

dodge had factory nv4500 behind cummins from '91.5 through 2000-ish till the nv5600 took over.

A small clearification here, Dodge didn't use the 4500 behind the Cummins until 94 when the new body style appeared. They used the G360 Getrag until the end of the 93 model run.
Travis..

Nice clean swap, My 2001 24v in my 85 K30 took long time and there are always things to do different,, GOOD Job if anyone can provide a clean dependable part number for this mysterious A/C bracket that I keep hearing about, PLEASE PM ME<,,,,, the one I had Cummins said didnt exist. thus I have the Dodge compressor, and not enough room to mount it near the frame, (long storry and idealics of an idiot:shaking:)

again,,, GOOD JOB GUYS

http://i144.photobucket.com/albums/r193/demon_044/Trucks/Alcoa22mounted013.jpg
http://i144.photobucket.com/albums/r193/demon_044/Trucks/swap026.jpg

I apologize in advance for hijacking this thread, but I have to say this. I'm usually not a fan of big rig wheels on a pickup, but I must say this truck looks REALLY good with them. I especially like the spike lug nut covers.

Scott

http://www.bluetorchfab.com/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=1908&g2_serialNumber

Nice clean swap, My 2001 24v in my 85 K30 took long time and there are always things to do different,, GOOD Job if anyone can provide a clean dependable part number for this mysterious A/C bracket that I keep hearing about, PLEASE PM ME<,,,,, the one I had Cummins said didnt exist. thus I have the Dodge compressor, and not enough room to mount it near the frame, (long storry and idealics of an idiot:shaking:)

again,,, GOOD JOB GUYS

I can get you the part # for that high mount AC bracket. I don't know it off hand but i can get it. I'll let you know..........

Thanks,,, that would be great, like I said the one I have,(dont have it in front of me) keeps turning up where ever I look but it keeps turning up as a bad part number,,, was going to talk the the John Deere parts guy as some of Deeres smaller tractors used that engine and had A/C.....

sorry handn't forgot about the AC bracket. but I've only seen an ISX and a couple ISLs and ISMs come through. usually we have something in the allison shop that has a B series in it.

thanks for the update. will be cking into building an A/C setup this summer and am looking at scrounging up the peices.

good call 12 valve with p -pump (right awnnnnnnnnn ):smokin::smokin:
wish I had it !!

i am going to do the same conversion in my 2000 chevy crewcab dually, i have access to both 12 valve and an 05 24 valve with tranny and transfercase. which motor would you guys recemmend. i am like everyone else, i will be upgrading parts to make more power and smoke! any and all help will be great

depends on how much wiring harness you want to make. the 12v needs quite literally 2 power wires to make it run. and the '05 while technically has 24 valves is a HPCR (high pressure common rail) engine. totally do able but much more technologically advanced than a mechanical 12 valve. you will need the whole engine harness and ECM for the '05 for sure.

thankyou for the help, i am going to go with the 12 valve, hopefully it will turn out as nice as your truck

that blue torch truck is sick. i have seen it at their shop..

what wheels and tires are on the white dually above??

they're 22.5" Alcoas off a Freightliner. Freightliner Directionals actually. Shaved to 22.0" tires are Nitto 420s 305/45r22

I bought a K2500 6.5 turbo diesel. 3 months later the engine is shot. looking for power and something that will tow plus last. would a cummins hook up to a auto trans for daily driving? and i have a 2inch body lift. how hard was it to do? i am 19 and have been working on cars my whole life. but not diesel. but i want to have it work i am willing to take time to get the A/C working but need the truck running to make money. would putting a 6.6 be better and or faster? or the cummins?

also i bought the truck for 3g and don't really want to spend more than 5 more on it

you can do it for under 5k easy, if you do it yourself, you can buy an adapter to hook cummins to your 4l80. 2inch body lift helps fit it. cummins is way easier then a 6.6 swap and more support. plus more reliable in my opinion. find a motor and get to fabin.

CAC is slightly tapered back to clear the light casing. I'm ok with it. I've got 2 16" electrics that will go on the front as pushers. as its tilted back i have room on the front.

not to high jack your thread. but here it is just before the 6bt swap with the 22" alcoas, no lift.

http://i144.photobucket.com/albums/r193/demon_044/Trucks/Alcoa22mounted013.jpg

as it sits now. with the new fenders and cowl hood. can't wait to get it done.

http://i144.photobucket.com/albums/r193/demon_044/Trucks/swap026.jpg


Damnit Demon!! I think I have been driving by your truck for a while now..... always checking it out, and now I hear of this Cummins swap.... I have been thinking about making a similar move.... maybe I can check it out sometime??

/end jack

bringing this back to the top. i found a 6.5/nv4500/4x4 dually for cheap$$$. can i use the gmnv4500 and bolt the cummins to it?

yes and no..........

you need dodge bellhousing, and you need to swap input shafts in the nv4500, also NV needs to be HD style chevy 95 and up or you have to modify the input bearing retainer which is what i had to do.

this is how chevys should come from factory

Any updates on either of these trucks? I'm about to start a similar conversion with a 92 chevy 3500 CC dually. The donor truck is a 96 3500 srw 12v/NV4500 4x4. Any more pics and/or any hindsight do's & don'ts would be greatly appreciated.