I have had this truck pretty much complete for a while now. I do keep getting request for a build thread and pics of the swap. So here it is...



1995 Chevy Silverado 1500 Z71
3/4 Ton full drivetrain/ suspension swap
Cummins 6BT 1st gen swap
Built 727 Torqueflite trans
241DHD transfer case
custom made drive shafts
6" Rough contry lift
3" body lift
20" 8x6.5 -44 Fuel Hostage wheels
37.5" Tires

1st gen 6BT when bought




My 95' Silverado 1500. I had previously did a 6" lift kit and 18" wheels on 35's to this truck.



I had the engine seperated for easier storage while I collected parts.


The start:

First things first. I pulled everything out of the truck I wasnt going to reuse. This included the 200k SBC350 and trans. Full suspension, Diffs, Rear end, Entire front end, brakes, etc...






I replaced everything I tought would need to be new when doing the 3/4 ton swap. Brakes, studes, calipers, all ball joints got replaced, swaybar links, etc. Theres was some modding that needs to be done to get the 3/4 ton upper ball joint to fit the 1/2 ton upper control arm. I really just redrilled the holes. The arms will need to be shortened for correct camber. I plan to do this in the summer.

 

The 1st gen came with a passenger side drop T case, I needed a Drivers drop one. I found a 241DHD from a 05' Ram on CL for $200 with yoke. So I hoped on the deal. Fits perfect.


Cummins installation
I bought brand new 1st gen mounts since there the closest to the original mounts. New mounts only ran me $40 for both so why not. I center the engine in the bay and had to drill one hole on each frome mount to get the dodge mounts to fit fine. This worked out great.




I ended up needing more firewall clearance. I wanted to keep the oem cummins fan, which I did. I bought a 3'' body lift which helped all around for dirvetrain clearance.





I now have to swap stock wheels due to being 8 lug and height of my garage door. This complete swap was done in my home garage not in a full shop.


I shaved off the Dodge on the cross pipe and winkle painted the turbo housing and cross pipe.






While my trans was out getting fully built. I fitted the stock chevy radiator and fan shourd in the truck. I trimmed the upper shourd to fit and had to make up some coolant pipes to work.




Custom made driveshaft in the rear, also got the full floating 14 bolt rearend in. I also pulled the fuel pump and removed the pump. I then extended the fuel line from the sending unit to the bottom of the tank as a pickup tube. This keeps everything working like it should be.



I lucke dout and my buddy still had hi sold duramax exhaust still. I had to turn the mide pipe 90* to fit in the frame. I plasma cut a flange to fit the stock duramax one and welded that to my cummins down pipe. Exhaust fit great.


Got the built 727 trans back and tossed it in. I ended up making a custom floor shifter for the gear selector (see video). The stock cable for the column shifter wasnt long enough to throw all the gears reliably. I also made my own kick down cable setup to replace the cut oem one. The cross member is actullay in the oem spot. I had to drill the stock holes to acept bigger bolts and used some ploy mounts I had laying around.


I bought full digital gauges, trans temp/ boost/ exh temp.


I also swapped to a hydro booster for my brakes. Boought all new lines and ran my own plumbing to the steering pump. I cut out a ton of stock wiring. Ran the ignition just like it would of been with the 350. The fuel shut off is ran the same way.

 

I ditched the small temp filter and made my own intake tube with bigger filter.


Ran into a problem with a rotted freeze out plug. I replaced them all with a billit set.






Truck as it sits.


heres a couple videos of the truck. I have over 2k on this swap now. I am only running it 2wd til summer when I get the front driveshaft done. I have turned up the VE pump a bit since then. I will get more of my pics together for a more detailed build thread and replie to any questions.

YOUTUBE VIDEOS:

 

Reserved

 

Reserved for pics

 

Nice.