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Author Topic: 1996 C3500HD 454 4L80 Cummins Allison Conversion  (Read 863 times)

Tanman_2006

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1996 C3500HD 454 4L80 Cummins Allison Conversion
« on: February 22, 2017, 12:07:41 AM »

I have a 95 Dodge Cab and Chassis 2wd 5.9 Automatic that I got for cheap with a toasted trans and a pretty well trashed cab. I obviously don't want a dodge but the donor will be nice. I also have a 06 2wd 6 speed allison.

Now I've found a 96 3500HD 454 with a fresh engine and trans (driveable until I get parts gathered) and want to stuff the 5.9 and Allison in. I will be hauling cattle grossing over 30k probably so it needs to be able to take some hard use.

What all am I going to need?
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2013 Chevy 3500HD LML Crew Cab Cab and chassis 113k mile FOR SALE
1994 K3500 Single Cab Long Bed 6.5 NV4500 350k Miles
1994 C3500 Single Cab Cab and Chassis 5.7 NV4500 113k Miles
1993 K3500 Single Cab Cab and Chassis 6.5 NV4500 240k Miles

Raymo

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Re: 1996 C3500HD 454 4L80 Cummins Allison Conversion
« Reply #1 on: February 22, 2017, 11:06:36 AM »

A lot  :D

Bell housing adapter of your choosing, can buy pricey adapters to keep the gm Bell or pick up a SAE#3 get up for a fraction of the price. Going to need a stand alone controller for the trans, already have a 6 speed so that will be easy to source.

I'm way deep in the same conversion with a few twists and turns, but once you've sourced the big parts it's a matter of time and money. A lot of both.
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'94 3500-HD, Cummins, Getrag, NP205. Shortend rear frame with a Pickup Bed. Dana 60 front, stock 80 rear.

'03 2500-HD 8.1 and Allison

Tanman_2006

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Re: 1996 C3500HD 454 4L80 Cummins Allison Conversion
« Reply #2 on: February 22, 2017, 11:56:16 AM »

I'm thinking cac on the allison control with a 06 shift lever rigged for manual shift option.

I know where I can get a bread truck adapter but heard they put the engine at a funky angle. Sae 3 is too thick iirc.

I was thinking of using a 01-04 duramax inner cooler if the cummins sits far enough back to clear a mechanical fan (I don't want electric and I know it's a tight fit in a regular 3500).

I don't think 4.63's will be an issue with the .61 OD and 245 tires.

I know there are brackets available for the alt and AC. Power steering/hydro boost has me lost.

And then the parking brake for DOT.
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2013 Chevy 3500HD LML Crew Cab Cab and chassis 113k mile FOR SALE
1994 K3500 Single Cab Long Bed 6.5 NV4500 350k Miles
1994 C3500 Single Cab Cab and Chassis 5.7 NV4500 113k Miles
1993 K3500 Single Cab Cab and Chassis 6.5 NV4500 240k Miles

RPF207

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Re: 1996 C3500HD 454 4L80 Cummins Allison Conversion
« Reply #3 on: February 22, 2017, 12:19:26 PM »

Might have to clearance the cab floor. For sure have to modify engine and trans crossmembers. HDs don't have any more front to back engine room than a regular pick up but do have enough vertical potential so that you won't need a body lift, just notch the engine crossmember. Cummins engines are very tall and very long compared to any engine GM had in there. Same with the Allison, pretty big compared to the 4l85e. Don't forget to keep that Allison cool while towing that much weight. a separate oilcooler with electric fan keeping the temps under 200* (preferably 170*) will give that trans a lot of extra life.
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1999 chevy HD 4x4 135.5" 6.5 nv4500 bw4470 Dana 70 HP 10 lug front

Due to recent budget cuts the light at the end of the tunnel has been turned off

Raymo

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Re: 1996 C3500HD 454 4L80 Cummins Allison Conversion
« Reply #4 on: February 22, 2017, 05:15:45 PM »

CAC is an overpriced joke. Spent about an hour on the phone with them and can tell you it's not worth it. Lots of misinformation and upselling.

I went with Jason at transmissiontuner.net. tuned TCM to my specs, did an excellent job on my harness and knows his stuff.
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'94 3500-HD, Cummins, Getrag, NP205. Shortend rear frame with a Pickup Bed. Dana 60 front, stock 80 rear.

'03 2500-HD 8.1 and Allison

Raymo

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Re: 1996 C3500HD 454 4L80 Cummins Allison Conversion
« Reply #5 on: February 22, 2017, 05:17:14 PM »

Also, I paid half for everything thru Jason of what CAC wanted.
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'94 3500-HD, Cummins, Getrag, NP205. Shortend rear frame with a Pickup Bed. Dana 60 front, stock 80 rear.

'03 2500-HD 8.1 and Allison

RPF207

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Re: 1996 C3500HD 454 4L80 Cummins Allison Conversion
« Reply #6 on: February 22, 2017, 07:22:45 PM »

That's good to know!
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1999 chevy HD 4x4 135.5" 6.5 nv4500 bw4470 Dana 70 HP 10 lug front

Due to recent budget cuts the light at the end of the tunnel has been turned off

Tanman_2006

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Re: 1996 C3500HD 454 4L80 Cummins Allison Conversion
« Reply #7 on: February 22, 2017, 07:59:18 PM »

Thanks for the info! I'll check them out!
Logged
2013 Chevy 3500HD LML Crew Cab Cab and chassis 113k mile FOR SALE
1994 K3500 Single Cab Long Bed 6.5 NV4500 350k Miles
1994 C3500 Single Cab Cab and Chassis 5.7 NV4500 113k Miles
1993 K3500 Single Cab Cab and Chassis 6.5 NV4500 240k Miles

jd8420

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Re: 1996 C3500HD 454 4L80 Cummins Allison Conversion
« Reply #8 on: February 22, 2017, 08:08:30 PM »

Some of the newer bread trucks have a 4 cylinder Cummins like the ISB170 and come with an Allison 1000 with an emergency brake on the back of the transmission similar to the 3500HD.
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3500HD 4X4 454/NV4500

RPF207

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Re: 1996 C3500HD 454 4L80 Cummins Allison Conversion
« Reply #9 on: February 23, 2017, 06:57:35 AM »

Not only the 4bt/Allison but also the 6bt/Allison 1000. You can buy whole frame cuts from $3,500-$5,000 with everything you need to make it run
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1999 chevy HD 4x4 135.5" 6.5 nv4500 bw4470 Dana 70 HP 10 lug front

Due to recent budget cuts the light at the end of the tunnel has been turned off

Tanman_2006

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  • Posts: 7
Re: 1996 C3500HD 454 4L80 Cummins Allison Conversion
« Reply #10 on: February 23, 2017, 08:16:13 AM »

I've never seen one listed, is there certain years?

Sounds great other than. The fact I have everything I need mechanically as far as a Cummins and Allison and don't have another 3500 to spend for the same set up. I've got a 10k budget to get up and running and don't want to blow all my money on having 2 of everything.
Logged
2013 Chevy 3500HD LML Crew Cab Cab and chassis 113k mile FOR SALE
1994 K3500 Single Cab Long Bed 6.5 NV4500 350k Miles
1994 C3500 Single Cab Cab and Chassis 5.7 NV4500 113k Miles
1993 K3500 Single Cab Cab and Chassis 6.5 NV4500 240k Miles

Raymo

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Re: 1996 C3500HD 454 4L80 Cummins Allison Conversion
« Reply #11 on: February 23, 2017, 05:19:12 PM »

Another thing I wanted to point out was the options for a tps that he offered. CAC wants to sell you theirs but he can build your harness to use the Dodge tps you already have. I ended up using a genuine Allison piece but he made it clear what else could be done.
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'94 3500-HD, Cummins, Getrag, NP205. Shortend rear frame with a Pickup Bed. Dana 60 front, stock 80 rear.

'03 2500-HD 8.1 and Allison