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02 5.9 cummins in to a 96 chevy 3500

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ArleninOr
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PostPosted: Thu Jan 11, 2018 2:50 pm    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

Walter, check all of your connections in the light circuit. also check the multi function switch in the steering column. That switch can cause a lot of problems.
 
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Destroked 450
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PostPosted: Thu Jan 11, 2018 3:47 pm    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote


That 93 1st gen Cummins doesn't need much wiring.
Ignition wire to the inj pump, water temp, oil pressure, wire up the starter. Not sure how GM gets their tach signal if you have one and want it to work.

Company called Diesel Conversion Specialist makes harnesses for Ford conversions, they may be able to make up one for your Chevy.
 
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ArleninOr
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PostPosted: Thu Jan 11, 2018 4:28 pm    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

Destroked, son and I put an 81 chev cab and frontend on a 91 Dodge frame. Used all of the chev wiring to hook up the gauges. only problem we had was the wire going to some of the sensors were too short. Cut and splice. Worked great. 650 hp on a dyno. Kinda scary to drive. But fun and proved to his buddies that this "Old Man" knew what he was doing. They don't say " you can't do that" anymore.
 
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Destroked 450
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PostPosted: Thu Jan 11, 2018 4:48 pm    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote


Mine's a 97 215 p pump engine in a F-450
It's my primary tow vehicle so keeping it under 400hp for durability.
Did the conversion 4 years ago but the used engine wasn't much good, so we built a new engine with aftermarket cam, injectors and turbo, swapped it in 2 years ago while doing a 08 front frame swap converting the front to coil springs for a better ride and sharper turning radius.
Finished it up a couple months before my 60th bday.
Wife drives around in a super charged Z71, not to often you see a 16 year old wanting grandma's old truck.
 
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Walter Buller
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PostPosted: Thu Jan 11, 2018 8:10 pm    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

Destroked, I believe I already talked to DCS. I know how simple the basic wiring is. Not much more complicated than the wiring on a MF 135 with a
Perkins. But we don't have a problem there. I can crank the motor and drive the truck right now. Already have. The problem is the interference we're
getting to the rest of the wiring every time we either turn the lights on or press the brake pedal. Doing either one apparently robs everything else
of current. No dash gauges, no turn signals, no power door locks or windows. Can't get an inspection sticker like that.
 
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Walter Buller
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PostPosted: Thu Jan 11, 2018 8:30 pm    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

We didn't use a brass insert clutch but we used the heaviest duty one under that that we could find. I honestly can't remember its composition it's
been so long. Can those shafts be replaced with larger ones, or would it be necessary to change the entire transmission? We haven't done anything to
effect the Hp. It's still the stock 160. I never had a problem pulling 20K# loads with my "93 Dodge D-250 that was converted into a D-350 dually and
has the 5 spd. Getrag tranny, original 160 Hp output. I don't know the composition of the clutch in it but probably just stock. We're about to find
out because it finally wore out and is in the shop for a clutch job.
 
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PretendFarmer
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PostPosted: Fri Jan 12, 2018 7:43 am    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

I don't think its worth the effort to convert a light duty NV4500 to a heavy duty version. Honestly if it were me and if you could afford the break down, I would just drive it and if you ever snapped the input then worry about it.
Your chances of snapping the input with the stock 160hp is pretty slim I would say considering that I think the light duty NV4500 is rated for 400ft-lbs input and that's where your 160hp cummins is at.
Take a look see here: http://www.dieselhub.com/trans/nv4500.html
That doesn't list the light duty input torque. I can tell you for sure that I was putting over 500ft-lbs through my NV4500HD.
 
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Walter Buller
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PostPosted: Fri Jan 12, 2018 5:29 pm    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

I was talking with my mechanic today and he reminded me that before he stabbed the Chevy NV4500, he removed the input shaft and replaced it with the
larger HD version. I had forgotten. So we are good to go there. I drove the truck today about 5 miles to the tire shop so they could mount the 6 new
10 ply tires that arrived this morning. These Thunderer CLT Commercial Duty tires from Thailand are impressive, have excellent customer reports, and
are unbelievably inexpensive at $108 each. You just can't beat 6 load range E truck tires with a reputation for extraordinary strength and long life,
and that come with an unconditional 45 day free replacement, no questions asked, and a one year practically unconditional free road hazard warranty
for $651. But we are still working on the wiring issue. Very aggravating.
 
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David G
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PostPosted: Tue Jan 16, 2018 8:31 am    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

I would put a 454 in it before going to all that work.
 
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Destroked 450
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PostPosted: Tue Jan 16, 2018 10:16 am    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote


Sounds like a bad ground somewhere.
I've had it happen on semi's, one bulb not grounded good can draw thru the whole system making other lights not work.
Engine to body, engine to frame grounds all good?

Years ago a neighbor was having issues with tail lights not working, took a bit of searching but the right front marker light was shorted.
You had some of the front end apart doing the engine swap, did you get all of the grounds for the front lights reconnected?

John
 
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mattofvinings
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PostPosted: Thu Feb 08, 2018 4:46 am    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote


I would suggest looking at the actual headlight on-off switch.

This is from the previous generation truck but I had a lot of lighting issues caused by a burned connection inside the old push-pull switch. It had 7 or 8 male lugs on it and the organizer comb for the female lugs was long gone. Only one combination was correct. It took a lot of looking at the wiring diagrams and ringing out the switch with a continuity meter to figure out the problem.

Eventually realizing the problem (too much electrical load on the parking lamp circuit when pulling the Goose) I installed a 30A relay to do the actual switching of lights ON or OFF. The push-pull only sends milliamps now to the relay coil.

However a lot of unexpected behavior of the internal and external lighting resulted.

I was lucky enough to find a Haynes (OEM -GM) printed manual for my truck on ebay. The wiring diagrams inside really helped.
 
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