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Old September 14th, 2011, 09:16 PM   #1
sbcrichie
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97 chevy cummins swap

I am about half way thru a cummins swap on a 97 crew cab chevy. It was originally a 454 manual 4x4 truck. I am swapping in a 93 first gen cummins, reusing the chevy nv4500 and borg warner tcase. I switched the input shaft and retainer in the tranny and am running a 94-02 dodge clutch and bellhousing setup.




Cut the lip off the bottom of the frame right below the motor mounts and used counter sunk bolts on the top three differential case bolts.

Fits in pretty nice obviously cant use the dodge ac mount. So im using a freightliner mid mount ac bracket and compressor, and making some mounts to use the chevy alternator





I got a big intercooler from the yard and cut the tanks off and shortened the core hieght wise and fabed my own end tanks. Also had to open up the core support to fit the intercooler between the radiator and condenser. Decided to get a narrower radiator for easier intercooler plumbing and I didnt want to cut the main supports out of the core support.


Attached Images
File Type: jpg cummins swap 1.jpg (27.1 KB, 7721 views)
File Type: jpg cummins swap 2.jpg (26.1 KB, 4597 views)
File Type: jpg cummins swap 3.jpg (23.1 KB, 4908 views)
File Type: jpg cummins swap 4.jpg (26.5 KB, 7754 views)
File Type: jpg cummins swap 5.jpg (28.1 KB, 4784 views)
File Type: jpg cummins swap 8.jpg (21.7 KB, 4366 views)
File Type: jpg cummins swap 6.jpg (24.7 KB, 4129 views)
File Type: jpg cummins swap 7.jpg (25.5 KB, 4305 views)
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Old September 14th, 2011, 09:18 PM   #2
boggin-machine
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you slammed a cummins truck???? tell me it will go back up to stock and its just lowered for ease of working on it please.
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Old September 14th, 2011, 09:20 PM   #3
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Lookin' good
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Old September 14th, 2011, 09:24 PM   #4
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Lol! The borg warner tcase will hit the torsion bar crossmember so i took out the torsion bars and crossmember. You can notch the crossmember or run a different tcase but i dont see any reason to take out the one ton tcase and put in a half ton tcase behind a diesel and i want air bags any ways so it is sitting on the bump stops right now until i get the air bags fabbed up.
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Old September 14th, 2011, 09:25 PM   #5
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Thanks raymo! Im guessing that chevy in you avatar has a cummins?
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Old September 14th, 2011, 09:26 PM   #6
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hells yea. keep the pics coming. i wanted to do this to a older burban but found it easier to just buy a 7.3 excursion
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Old September 14th, 2011, 09:30 PM   #7
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Will do!
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Old September 14th, 2011, 09:31 PM   #8
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ive wanted to do this for some time to but wasnt much a write up on anything like this. im very jelous for sure!
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Old September 14th, 2011, 09:34 PM   #9
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Its actually been done alot. Id like to take credit for being a trailblazer here but i cant.
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Old September 14th, 2011, 09:36 PM   #10
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when i as looking around for sucha swap i couldnt find much detailed info on it.
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Old September 14th, 2011, 10:09 PM   #11
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Quote:
Originally Posted by sbcrichie View Post
Thanks raymo! Im guessing that chevy in you avatar has a cummins?
Affirmative. It's a never ending project, but at least I've got a solid drive train to build up from.

I've got the same engine as you, not much of a power house out of the box, but as we all know there is plenty of room for improvement

I think you'll be happy with it, and the air bags will make it awesome.
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Old September 14th, 2011, 10:12 PM   #12
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when i as looking around for sucha swap i couldnt find much detailed info on it.
Set the engine in, and the rest will fall into place

Unless you go ubervalver... then it's a shitload of work from what I've seen.
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Old September 15th, 2011, 05:14 AM   #13
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Set the engine in, and the rest will fall into place

Unless you go ubervalver... then it's a shitload of work from what I've seen.
Yes the simplicity of the first gen is amazing one wire to the fuel solenoid and crank to the starter and the motor will run, mechanical lift pump on the side of the block so you dont even need a electric fuel pump. From what iv heard this motor can make 280 horsepower with some pump mods and a smaller exhaust housing on the turbo. A 24 valve makes around 230 stock i beleive. I will have a little more wiring work though because i want all the stock gages to work and the cruise and ac too.
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Old September 15th, 2011, 05:34 AM   #14
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If i cant find a suitable truck to buy in the next few weeks im gonna be swapping a cummins into some thing. This is nice. A friend of mine has a 98 chevy that he has been putting a common rail into for about 5 years. It has a solid axle and all in front. But i dont think he will ever finish it.
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Old September 15th, 2011, 05:39 AM   #15
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Common rail would be a whole nother animal as far as the wiring goes i would think.
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Old September 15th, 2011, 06:28 AM   #16
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more pics more pics more pics
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Old September 15th, 2011, 06:25 PM   #17
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more pics more pics more pics
Pics? If you live in sturgis you can just come out and see it!
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Old September 15th, 2011, 09:58 PM   #18
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Very, very cool.
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Old September 16th, 2011, 07:44 PM   #19
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Some more pics. Didnt get much done today just the manifold on and torqued, turbo on, looked at down pipe a little, ac pump on and checked for belt length, and got a 95 accumulator filter to look at down pipe clearance.









Attached Images
File Type: jpg cummins swap 11.jpg (20.3 KB, 4075 views)
File Type: jpg cummins swap 12.jpg (11.7 KB, 3860 views)
File Type: jpg cummins swap 13.jpg (20.6 KB, 3906 views)
File Type: jpg cummins swap 14.jpg (19.2 KB, 3881 views)
File Type: jpg cummins swap 15.jpg (19.9 KB, 3900 views)
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Old September 16th, 2011, 08:05 PM   #20
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