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02 5.9 cummins in to a 96 chevy 3500

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johndeeregreg
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PostPosted: Sun Jan 07, 2018 10:17 pm    Post subject: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

wondering how big of a job is it to put a 5.9 cummins out of a 2002 dodge 2500 in a 96 chevy 3500? found a dodge on craigslist that rolled and seems pretty reasonable. my little 350 don't handle the big loads i throw at it like i would like, i assume the cummins would be better? i assume if i were to do a project like this the whole engine and trans assembly would be swapped. seems there was someone on here not to long ago that did something like this. is it worth the hassle or is one better off to just save his pennies and buy a factory diesel pickup? any thoughts, ideas, or advise welcome
 
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ArleninOr
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PostPosted: Sun Jan 07, 2018 11:20 pm    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

Whole lotta work. Can be done, just don't know if it is cost effective.
 
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PretendFarmer
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PostPosted: Mon Jan 08, 2018 4:24 am    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

Life would be easier for you if you dropped in a 12 valve instead. In 98.5 they came out with the 24 valve which is computer controlled.
12 valve swaps are the most common for a reason.
 
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johndeeregreg
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PostPosted: Mon Jan 08, 2018 6:39 am    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

ok thanks, i haven't done any research on a project like this and thought this would be a good place to start. in all reality its a project i will
probably never tackle, just saw the add and it got me thinking.
 
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Destroked 450
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PostPosted: Mon Jan 08, 2018 8:00 am    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote


Swapping a 12v Cummins into a truck with manual trans is easiest which is what I did (04 F-450, 12 Cummins, Ford ZF6 6spd manual)

24v swap also requires using the Dodge ECM and involves a fair amount of wiring.

Cummins engine is longer, to use the mechanical fan the trans will need moved back 2-3", this will require modifying trans crossmember, shift linkage and drive shafts.

Take the cost of the rolled Dodge and add min $2K and max $5k to the total cost of the conversion (some have spent much more), then decide if your present truck is worth spending that much on, do you use it enough to justify the cost, do you plan to keep it long enough to drive to cost back out.

Cummins Diesel Forum has lots of threads in the Cummins Conversion section about doing such swaps.

In my case the swap was worth it.
The truck was a rust free low mile (under 100K mile) former fire truck (stored inside) with blown engine (bought cheap). Swapping in a Cummins was less than replacing the blown 6.0.
Short of being wrecked I plan for this truck to be the last heavy duty truck I purchase, I have zero interest in a new diesel pickup, should I be forced to replace this truck I'll probably go back to a gas engine.
 
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Mike M
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PostPosted: Mon Jan 08, 2018 11:00 am    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

I'd be looking for a chevy 454 it should drop right in ! Good power it will get it done !
 
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Walter Buller
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PostPosted: Tue Jan 09, 2018 1:02 pm    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

We put a "93 Cummins into a "94 Chevy dually. Spent maybe $3800 on parts, which includes the low mileage motor, the "98 Chevy NV4500 5 spd. tranny, the all aluminum radiator, special bell housng, new clutch pack, new flywheel, drive shaft work, exhaust pipe adapter, and miscellaneous stuff. Had to lift the cab 2", and shove the motor all the way back against the firewall. The whole job is easier if you first remove the grill and everything else between the fenders, except the bumper and lower supports of course. We installed a 6" turbo-back straight exhaust, using an adapter I found on Amazon, but we still had to heat it with a rose bud in the curve in order to beat it inward somewhat where it passed by the tranny support, otherwise it wouldn't fit. We are now driving the truck. It does great. The only issue we have is some problem with the wiring. When the lights are on, either by way of the headlights burning or when braking, the turn signal;s and dash gauges stop working. We installed several additional grounds and disabled the ABS system to no avail. Next we will get an adapter for connecting the Dodge motor to the Chevy truck, disconnect the auxillary gauges, and see if that solves the problem. This project has taken over 6 years, working when we had the time. Would I do it again? Not sure. A good bit of the time was involved in finding the right parts, making mistakes, correcting them, and doing it again. I expect therefore that the second time would be a lot easier. We learned a lot, had fun, and now have a combination of the best frame and the best motor.
 
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504
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PostPosted: Tue Jan 09, 2018 8:19 pm    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

Just a thought,I just did a tune up on my 96-3/4ton. plugs,cap,wires and rotor made a great big difference in the old girl. The chain store wanted $12.99 per plug,I bought everything from RO for $48.00. Mine is a little slower pulling than my SILs Duramax,but I run 65 mph with the gas burner, and he can run 70mph pulling the same trailer. I can tune mine up for $50.00 and he can t buy an injector for that. I get 10 mpg and he gets 15mpg, and his cost a heck of a lot more than mine.
 
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PretendFarmer
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PostPosted: Wed Jan 10, 2018 3:50 am    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

Walter, why did you use a Chevy NV4500 and not the Dodge NV4500HD? Chevy NV4500 has a granny low and a smaller input and output than the Dodge HD version and that Chevy granny low isn't needed with the diesel.
 
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Walter Buller
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PostPosted: Wed Jan 10, 2018 9:15 am    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

Pretend Farmer. At the time, we were trying to hold costs down as much as reasonably possible. The "98 Chevy NV4500 came available at $500. Plus we
didn't really know much about the differences between Chevy's and Dodge's anyway. Not that it matters much anymore: My hauling days are over. My wife
developed some serious health issues during the conversion so I can't be away from home on long trips anymore. What else can you tell me about the
differences? Are the gears the same size except for the granny? I decided to put 6 new tires on it. Going with Thunderer Commercials size 235 x 85-16.
My son has them on his Chevy. Next will be a new windshield. Still haven't figured out the wiring problem. The motor didn't come with a wiring
harness, so we made do. When I turn the headlights on or press the brake pedal, all the dash gauges stop working, so do the power door locks and
windows and turn signals. We installed auxillary gauges on the dash and ran a separate wire from a new toggle switch to the headlights and several
additional grounds all to no avail. The auxillary gauges keep working, but of course they don't include the fuel gauge or the speedometer. Putting a
new brake light switch on today to see if that solves the problem.
 
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Bob
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PostPosted: Wed Jan 10, 2018 9:45 pm    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

Walter, Grab a 12 Volt unpowered test lite.

Connect the test lite wire directly to the ground post at a battery.

Probe the black (ground) wire connection at a headlight with the test lit probe.

Obviously, test lite should not light.

Continue to hold the test lite in position on the ground at a headlamp, and have someone turn on the headlight switch. Let us know what the test lite does!
 
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PretendFarmer
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PostPosted: Thu Jan 11, 2018 5:10 am    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

Walter,
As far as I know the only difference between the Dodge NV4500HD and the light duty Chevy NV4500 is the 1 1/8" input, smaller output, and granny low. But I don't think all year chevy NV4500's had the granny low.
You can snap that input with your Cummins but it would be unlikely if you have a single disk organic clutch as they don't grab hard.
If you had a ceramic clutch in it you probably would've snapped it already. The NV4500HD has a 1 1/4" input and that's a big difference.
 
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Walter Buller
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PostPosted: Thu Jan 11, 2018 10:54 am    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

Bob, We did what you suggested but nothing happened. The test light did not come on.
 
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Bob
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PostPosted: Thu Jan 11, 2018 12:01 pm    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

Interesting... If it truly isn't the ground side, it has the be a common point in the wiring on the power feed side... possibly in the "power distribution box" area under the hood. I have factory wiring diagrams for that year, if I remember and get a little time later, I'll take a look for a common point all those systems that "go down" share.

I'd sure like to know what you have going on... HAS to be something very simply that was not tightly connected, or damaged during the engine swap.
 
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Walter Buller
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PostPosted: Thu Jan 11, 2018 2:14 pm    Post subject: Re: 02 5.9 cummins in to a 96 chevy 3500 Reply to specific post Reply with quote

Bob, if you can figure it out I will include you in my will. This is the only thing preventing me from driving the truck. My mechanic is the best mechanic I know but he had never before done such a conversion. We have worked on this project as time and funds have permitted, over 6 years now, but for a total price of about 5 grand which includes EVERYTHING, motor, tranny, tires, windshield, the works, plus considering the fact that he isn't charging me for labor, I feel like I did pretty good. I just wish we could solve this wiring problem. Several people told me that there is an adapter that allows you to connect a Cummins motor wiring harness to a Chevy wiring harness. I haven't yet found that adapter, but the motor did not come with a wiring harness anyway. Do you think it would help to find one and use it with that adapter?
 
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