97 chevy cummins swap - Great Lakes 4x4. The largest offroad forum in the Midwest

sbcrichie · September 14th, 2011, 10:16 PM

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.

boggin-machine · September 14th, 2011, 10:18 PM

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.

Raymo · September 14th, 2011, 10:20 PM

Lookin' good

sbcrichie · September 14th, 2011, 10:24 PM

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.

sbcrichie · September 14th, 2011, 10:25 PM

Thanks raymo! Im guessing that chevy in you avatar has a cummins?

chevotass · September 14th, 2011, 10:26 PM

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

sbcrichie · September 14th, 2011, 10:30 PM

Will do!

boggin-machine · September 14th, 2011, 10:31 PM

ive wanted to do this for some time to but wasnt much a write up on anything like this. im very jelous for sure!

sbcrichie · September 14th, 2011, 10:34 PM

Its actually been done alot. Id like to take credit for being a trailblazer here but i cant.

boggin-machine · September 14th, 2011, 10:36 PM

when i as looking around for sucha swap i couldnt find much detailed info on it.

Raymo · September 14th, 2011, 11:09 PM

Quote:

Originally Posted by sbcrichie

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.

Raymo · September 14th, 2011, 11:12 PM

Quote:

Originally Posted by boggin-machine

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.

sbcrichie · September 15th, 2011, 06:14 AM

Quote:

Originally Posted by Raymo

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.

Fullsize4life · September 15th, 2011, 06:34 AM

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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sbcrichie · September 15th, 2011, 06:39 AM

Common rail would be a whole nother animal as far as the wiring goes i would think.

caveman · September 15th, 2011, 07:28 AM

more pics more pics more pics

sbcrichie · September 15th, 2011, 07:25 PM

Quote:

Originally Posted by caveman

more pics more pics more pics

Pics? If you live in sturgis you can just come out and see it!

Strangler · September 15th, 2011, 10:58 PM

Very, very cool.

sbcrichie · September 16th, 2011, 08:44 PM

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.

Dazz · September 16th, 2011, 09:05 PM

Dayum

September 14th, 2011, 10:16 PM	#1
sbcrichie R&R Fabwerks Join Date: 08-30-09 Location: sturgis/michigan Posts: 1,650 iTrader: (10) Mentioned: 8 Post(s)	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 Thumbnails

September 16th, 2011, 08:44 PM	#19
sbcrichie R&R Fabwerks Join Date: 08-30-09 Location: sturgis/michigan Posts: 1,650 iTrader: (10) Mentioned: 8 Post(s)	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 Thumbnails

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September 14th, 2011, 10:18 PM	#2
boggin-machine Senior Member Join Date: 01-11-06 Location: Traverse city Posts: 11,843 iTrader: (32) Mentioned: 2 Post(s)	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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September 14th, 2011, 10:24 PM	#4
sbcrichie R&R Fabwerks Join Date: 08-30-09 Location: sturgis/michigan Posts: 1,650 iTrader: (10) Mentioned: 8 Post(s)	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.

September 14th, 2011, 10:25 PM	#5
sbcrichie R&R Fabwerks Join Date: 08-30-09 Location: sturgis/michigan Posts: 1,650 iTrader: (10) Mentioned: 8 Post(s)	Thanks raymo! Im guessing that chevy in you avatar has a cummins?

September 14th, 2011, 10:26 PM	#6
chevotass Senior Member Join Date: 11-02-06 Location: goodrich Posts: 7,511 iTrader: (23) Mentioned: 56 Post(s)	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

September 14th, 2011, 10:30 PM	#7
sbcrichie R&R Fabwerks Join Date: 08-30-09 Location: sturgis/michigan Posts: 1,650 iTrader: (10) Mentioned: 8 Post(s)	Will do!

September 14th, 2011, 10:31 PM	#8
boggin-machine Senior Member Join Date: 01-11-06 Location: Traverse city Posts: 11,843 iTrader: (32) Mentioned: 2 Post(s)	ive wanted to do this for some time to but wasnt much a write up on anything like this. im very jelous for sure!

September 14th, 2011, 10:34 PM	#9
sbcrichie R&R Fabwerks Join Date: 08-30-09 Location: sturgis/michigan Posts: 1,650 iTrader: (10) Mentioned: 8 Post(s)	Its actually been done alot. Id like to take credit for being a trailblazer here but i cant.

September 14th, 2011, 10:36 PM	#10
boggin-machine Senior Member Join Date: 01-11-06 Location: Traverse city Posts: 11,843 iTrader: (32) Mentioned: 2 Post(s)	when i as looking around for sucha swap i couldnt find much detailed info on it.

September 15th, 2011, 06:34 AM	#14
Fullsize4life Kicking Cancers ASS Join Date: 07-25-06 Location: Hart, Mi (next to silver lake) Posts: 18,753 iTrader: (7) Mentioned: 1 Post(s)	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. Best Car & Motorcycle Insurance \| Auto/Moto Protection Today \| FREE Trade-In Quote

September 15th, 2011, 06:39 AM	#15
sbcrichie R&R Fabwerks Join Date: 08-30-09 Location: sturgis/michigan Posts: 1,650 iTrader: (10) Mentioned: 8 Post(s)	Common rail would be a whole nother animal as far as the wiring goes i would think.

September 15th, 2011, 07:28 AM	#16
caveman GeoDude Join Date: 11-09-06 Location: Sturgis MI. Posts: 2,525 iTrader: (13) Mentioned: 1 Post(s)	more pics more pics more pics

September 15th, 2011, 10:58 PM	#18
Strangler Senior Member Join Date: 12-12-05 Location: Howell Posts: 4,870 iTrader: (53) Mentioned: 42 Post(s)	Very, very cool.

September 16th, 2011, 09:05 PM	#20
Dazz Senior Member Join Date: 07-27-09 Location: Spring Arbor, Michigan Posts: 144 iTrader: (7) Mentioned: 0 Post(s)	Dayum