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Old 03-19-2014, 09:05 AM   #1 (permalink)
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Cummins swap parts thread

with the growing number of Cummins engines being swapped into offroad rigs I thought I would try to build a collection of parts that will aid with the install of the 6 cyl Diesel engine in less than "normal" applications

there have been many different pieces of equipment that the 5.9 cummins have been use in and therefore a lot of different cummins factory parts are available



here's what I've collected so far, if you have anything to add please try to post up photos and and much info as possible about the part (PN, application, engine SN)


also if anyone thinks this thread would be better in another section let me know and ill have it moved.

I found this particular engine in a tree mulcher

Engine Model QSB5.9
SN 46684123

here is a list of some of the parts I found


Upright drivers side AC unit

Compressor sits aprox 9" above mounting the surface on the front of the head


CF9093 Refrigerant Compressor
1 3043477 Washer, Plain 2 3/8 in
2 3902662 Nut, Hexagon Flange 2 M10 X 1.50
3 3906621 Screw, Hexagon Head Cap 3 M10 X 1.50 X 40
4 3912685 Spacer, Mounting 2
5 3916518 Screw, Hex Flange Head Cap 2 M10 X 1.50 X 125
6 3925962 Support, Ref Compressor 1
7 3930815 Bracket, Ref Compressor 2

Belt PN is 25-9476

[IMG][/IMG]

[IMG][/IMG]




[IMG][/IMG]

[IMG][/IMG]
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Last edited by 680oscar; 03-19-2014 at 09:43 PM.
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Old 03-19-2014, 09:16 AM   #2 (permalink)
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vertical T-stat housing/ upper hose connection




1 3903757 Bracket, Lifting 1

2 3900632 Screw, Hex Flange Head Cap 1 M8 X 1.25 X 35

3 3926972 Screw, Hex Flange Head Cap 2M8 X 1.25 X 70.

4 3285102 Housing, Thermostat 1

5 3923331 Gasket, Thm Housing Cover 1

themostat PN 3917324

upper rad hose is 1-3/4 ID



[IMG][/IMG]

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Last edited by 680oscar; 04-03-2014 at 09:05 PM.
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Old 03-19-2014, 09:29 AM   #3 (permalink)
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Big 8 groove Alternator

Unfortunately for some reason I think it only puts out 100amp







1 3052061 Screw, Hexagon Head Cap 1 1/2 - 13 X 1 in

2 3900631 Screw, Hex Flange Head Cap 3 M8 X 1.25 X 25

3 3903210 Nut, Hexagon Flange 1 M12 X 1.75

4 3902460 Screw, Hex Flange Head Cap 1 M10 X 1.50 X 25

5 3939905 Brace, Alternator 1


6 3903105 Screw, Hex Flange Head Cap 1 M12 X 1.75 X 150

7 3921737 Support, Alternator 1

Alt part number 5282836

Belt part number 3289268



[IMG][/IMG]

[IMG][/IMG]






Belt tensioner


1 3282081 Screw, Hex Flange Head Cap 1 M10 x 1.50 x 75.

2 3976831 Tensioner, Belt 1




[IMG][/IMG]

[IMG][/IMG]
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Last edited by 680oscar; 03-19-2014 at 09:09 PM.
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Old 03-19-2014, 09:34 AM   #4 (permalink)
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HX 35 turbo 90 deg. exh outlet





1 S 910 B Plug, Pipe 1 1/4 NPT

2 3902460 Screw, Hex Flange Head Cap 4 M10 X 1.50 X 25

3 3903652 Clamp, V Band 1

4 3910991 Pipe, Exhaust Outlet 1

5 3930717 Brace, Exh Out Connection 1

exh 90 outlet is 3" OD



[IMG][/IMG]

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Last edited by 680oscar; 03-19-2014 at 09:47 PM.
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Old 03-19-2014, 09:23 PM   #5 (permalink)
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Upright exhaust manifold


PN 3091683

[IMG][/IMG]






Turbo HX35W

PN 3599727




Turbocharger Oil Plumbing


1 3412320 Clamp, Hose 2

2 3900630 Screw, Hex Flange Head Cap 2 M8 X 1.25 X 20

3 3931973 Tube, Tur Oil Drain 1

4 3286499 Hose, Plain 1

5 3937706 Gasket, Oil Drain 1 Replace With 5264569

6 3934093 Connection, Tur Oil Drain 1

7 3037236 Seal, O Ring 1

8 3284244 Connector, Female 1 Replace With 3919687

9 3918562 Hose, Flexible 1

10 3924389 Washer, Sealing 2 7.2 mm

11 3931824 Seal, O Ring 1

3920706 Plug, Expansion



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Old 03-19-2014, 09:31 PM   #6 (permalink)
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Air Crossover Connection


1 3008469 Plug, Pipe 1 3/4 NPT

2 3026396 Clamp, Hose 2 2 1/16 - 3 in

3 3970409 Hose, Plain 1

4 3918109 Screw, Hex Flange Head Cap 3 M8 X 1.25 X 25

5 3919995 Screw, Hex Flange Head Cap 4 M8 X 1.25 X 90

6 3929085 Connection, Air Crossover 1

7 3938152 Gasket, Int Manifold Cover 1

8 3969988 Gasket, Connection 1

9 3991819 Cover, Intake Manifold 1

[IMG][/IMG]

[IMG][/IMG]
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Old 03-19-2014, 09:39 PM   #7 (permalink)
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vertical water inlet



1 3008468 Plug, Pipe 1 1/2 NPT

2 3008469 Plug, Pipe 2 3/4 NPT

3 3900679 Screw, Hex Flange Head Cap 3 M10 X 1.50 X 80

4 3906697 Seal, Rectangular Ring 2

5 3943149 Connection, Water Inlet 1

3943549 Connection,

6 131584 Pin, Roll 2

7 3943550 Connection, Water Inlet 1

lower rad hose is 2" ID






[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]
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Last edited by 680oscar; 04-03-2014 at 09:04 PM.
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Old 03-21-2014, 06:39 AM   #8 (permalink)
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Great info. I'm moving to the tow rig section though, as it sees way more diesel talk than the dodge forum.
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Old 03-21-2014, 08:45 AM   #9 (permalink)
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Sounds good, thanks
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Old 03-21-2014, 01:45 PM   #10 (permalink)
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Not to hijack, but some do like Common Rails for swaps

Here is some pertinent fuel system and injection related information:

2003/2004: Holset HE341 Turbo; 54/58/9

2004.5-2007: Holset HE351 Turbo; 60/60/9

04.5-07 HE351:
7 blade 60mm/60/9
19mm wastegate hole non divided
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Old 03-21-2014, 01:46 PM   #11 (permalink)
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2003-2004 trucks have an 8 hole nozzle

2004.5+ trucks have a 5 hole nozzle

Both trucks use a different piston bowl design also

555 5.9 and 6.7 injector nozzles have a wide spray angle due to a reentrant bowl design.

600/610 5.9 injector nozzles have a narrow spray angle due to the open non-reentrant bowl design.

555 motor: 143* injector spray impacts annular region of 113* piston bowl, concentrating combustion towards the piston dome. 8 hole nozzles with two injection events

600/610-series: 124* injector spray impacts central region of 140* piston dome, propagating combustion towards the cylinder wall. 5 hole nozzles with three injection events

-------------------------------------------

Additionally...........if you need/want a tad more fuel:

I have been running the 6.7L tubes for over a year, without any issues

The 5.9 tube outlet is .075" and the 6.7 tubes have a .120" outlet.

Cummins now supercedes the 5.9 tube P/N to the 6.7 crossover tube, although Bosch still offers the 5.9 P/N......

Most shops now list all 2003-2011 5.9L and 6.7L motors to use the same PN!

Bowl volumes are only .7cc different (~1.5%), so the choice doesn't significantly impact compression ratio - every .005" of compressed gasket thickness or piston protrusion is just over 1cc.

Re-entrant combustion is more efficient, reduces thermal flux into the block & head, and allows better piston geometry - especially regarding the top ring land - to handle the heat & pressure
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Old 03-21-2014, 08:00 PM   #12 (permalink)
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Great info. Glad it got moved here to the tow rig section. I don't follow the dodge section.

Nat
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Old 03-21-2014, 09:50 PM   #13 (permalink)
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Cummins to Ford, use a ps hose from 88 e150 with 5.8

And a 1st gen fan mount will save about an inch of clearance front to back over a 2nd gen truck

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Old 03-26-2014, 06:30 PM   #14 (permalink)
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this is a good thread. this is way better than finding the threads on 4bt swaps.
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Old 03-26-2014, 09:31 PM   #15 (permalink)
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4988751 new pump

The fist gen dodge 5.9 Cummins from 89 to 93 used a inferior lift pump. This is the mechanical pump that replaces it, and prevents injection pump failure due to low fuel pressure. This is not the same pump as the P pump Cummins engine used. The P pumped engine used a higher pressure lift pump that will alter your timing, due to the way the VE pump works. If trying to use a P pumped engine's lift pump on a VE engine It will need a regulator.
http://www.dieselbombers.com/5-9l-ro...lift-pump.html

First pic is the stock lift pump. When this one fails, it fills the crankcase full of diesel fuel.


Second and third pic are the manual replacement pump that eliminates the inferior pump. This mechanical pump pulls it's power from the camshaft lobe. When it fails, it simply starts leaking.

Parts needed.


Installed.



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Old 03-26-2014, 09:34 PM   #16 (permalink)
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For the sake of simple, we should almost keep this 12 valve only.

If we add all the new electric stuff, things will get overwhelming.

Nat
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Old 03-31-2014, 07:52 AM   #17 (permalink)
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Incase it hasn't been stated, on the 12v piston style lift pump, the fuel inlet threads are 1/2" NPT and outlet threads are M14 x 1.5 straight cut.
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Old 03-31-2014, 04:16 PM   #18 (permalink)
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on That lower mechanical lift pump, it REALLY makes the install easier if you make some studs for it in stead of bolting it down.
Be advised the holes in the block are metric thread.
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Old 04-01-2014, 09:33 AM   #19 (permalink)
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Any idea what size the vertical water inlet is?
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Old 04-03-2014, 07:05 PM   #20 (permalink)
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Many 12 valves had the engine oil fill tube coming off the front of the timing cover. Sometimes in cramped installs You need to delete this, and move the fill to the valve cover.

Valve cover with fill hole, plug, and seal.



Plug to fill the stock fill tube hole.



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Old 04-03-2014, 08:40 PM   #21 (permalink)
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That exhaust manifold above appears to just be a low mount manifold turned upside down. If a guy uses one of the valve covers with the fill hole, be warned that you can only put in about a quart at a time or it will overflow
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Old 04-03-2014, 09:07 PM   #22 (permalink)
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Lots of great info showing up in this thread!

Quote:
For the sake of simple, we should almost keep this 12 valve only.

If we add all the new electric stuff, things will get overwhelming.

Nat
I was hoping to keep this thread mostly external "bolt on parts" I agree that this thread could get very overwhelming with all the technical info available for the cummins engines.


Quote:
Any idea what size the vertical water inlet is?
I updated my posts to include the hose size



Quote:
That exhaust manifold above appears to just be a low mount manifold turned upside down.
i thought the same thing at first, its hard to tell from the pics but the turbo mounting flange is on an angle compared to the head mounting surface, the low mount common rail manifolds are at a 90deg compared to the head mounting surface.
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Old 04-03-2014, 09:28 PM   #23 (permalink)
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s-10 shift boots from the 90's + are great universal boot for nv4500 swaps, they have a large flat base that is screw down not push clip or lock ring retained.
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Old 04-03-2014, 09:55 PM   #24 (permalink)
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Originally Posted by S&H 4wd View Post
s-10 shift boots from the 90's + are great universal boot for nv4500 swaps, they have a large flat base that is screw down not push clip or lock ring retained.
THANKS i just did a nv4500 swap and for the time being im using a hat with a hole cut in the middle of it
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Old 04-05-2014, 07:22 PM   #25 (permalink)
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1992 Ford B700 chassis school bus, same as a F700 truck

Flywheel housing, 12 valve Cummins 5.9 to SAE 3 (Engine adapter.) This is the adapter to use any of the SAE 3 transmissions. (MDT trans) This one came with a 5 speed Eaton FS 5005A trans.
Starter is on the drivers side, turbo is on the passenger side. This is my favorite SAE 3 adapter so far, due to the 4 hole side mounts, and the starter being on the opposite side of the turbo\ downpipe.

Engine serial Number (ESN) 44796046






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