Basically, I have a 95 454/nv4500 2WD with 60k miles. The motor runs like a watch, but I am not going to deal with 4-6 mpg when loaded. I bought this vehicle for one purpose, to haul my rock buggy and camper, or to haul broke down cars that I occasionally buy.
I am moving forward with a diesel swap, 12 valve Cummins, I am hoping I can compile info here for our style trucks, and hopefully get some questions answered. Then do a build thread while in progress.
So to start Cummins choice:
It seems the 12 valve was built up to 1998, the 199(5?)(6?)-1998 motors have the P-pump which seems to be more desirable as they make and handle more power better. Also, the newer motors have a higher HP rating.
So buy a motor, first question is fitment:
Looking at the one swap I can see into a 3500HD, and several 2500/3500 swaps, it looks like the crossmember needs notching and that is about it. Autoworld makes motor mounts, but for the cost they do not seem that difficult to build yourself, gen 3 dodge (24 valve) mounts are said to be a stronger firmer mount.
Adapting to the trans:
The NV4500 will need a Dodge bellhousing, used they are hard to find but out there around $250, new seems to be in the $475 range. Our slave cylinder is on the passenger side, Dodge is driver, can the line from our slave be replaced with a Dodge style, and then a Dodge slave be used?
Accessories/Gauges:
This seems to be a no brainer, if you run the factory ECM and remove un-needed wiring for the old TBI setup you can retain the factory gauges. AC and Alternator can be mounted with Autoworld brackets, or home fabbed ones. Alternator gives Tach and Voltage, Factory AC compressor wil function as normal in regards to cycling. Stock 6.5 fuel sender can be used with removing the factory pump and putting a hose in, then you have a gauge. Factory oil pressure and coolant temp sensor can be adapted to Cummins motor and retain gauges.
Radiator/Intercooler/Condensor:
It sounds like the factory radiator is sufficient, a Dodge intercooler will go in front of it and the condensor with trimming of the core support. Does the intercooler go in front of the condensor?
Mechanical or electric fan:
I see electric fan swap threads, but some say it is not enough to cool the Cummins when towing, any thoughts?
Things I am currently unsure of,
Hydroboost:
There is a setup on the Cummins with I assume a gear driven vacuum pump. Is the 3500hd plumbed so the HVAC does not need vacuum as we have hydroboost? Can I find a Dodge motor with no vacuum pump and ready to run Hydroboost with adapter fittings to our system.
Wiring the Cummins:
I have found some info, but still researching, concerned about heater grid, water in fuel, wait to start systems etc.
Second tank setup:
I have one tank, do I plumb in a second tank with a dash controlled pump to auxillary fuel the primary tank when driving? Rather than dealing with a tank switcher, maybe the tank switcher is easy to add.
TBI wiring:
Once the swap is done and running, it would seem that I could go to the ECM pins and remove the TBI systems completely to clean things up.
Turning the motor up:
The key here is reliability, thinking a simple reman turbo, the HE style, a fuel pin/plate mod, timing, and possibly send the pump out to have it preventatively rebuilt.
Clutch:
Everyone online is running clutch setups that will cost more than what I will spend on a motor. For a normal guy with maybe a HE turbo, govenor spring and pump turned up slightly, how much clutch do I really need?
Speedo:
Where does our truck pull the speedo signal off the NV4500 at? Mine is currently INOP.
This is a good start, I am pretty obsessive so I will link, add what I find. I am thinking I am going to take my used engine, and replace all the gaskets, clean and paint the block, KDP etc. I will link relative how to's documenting those steps.
Can anyone help me with all this?