I have a 93 chevy 1 ton crew cab dually with a 6.5TD with mech.injection.I recently purchased a 5.9 cummins with p pump and allison 545 trans from a freightliner FL70.I have read about many people doing this conversion into 80s model chevys but not 90s.Will the cummins fit in the engine compartment? My truck has hydro boost and I am having trouble figuring out how to mate the power steering pump to the hydro boost sys.Also I havent figured out the tachometer wiring.All help with input and or pics will be greatly appreciated.

tach is a bitch, have to be kinda creative. You can get the alternator modified for the chev tach (and for internal regulation).
Its been done a lot, it fits. Whats that trans look like? Most people go with a 3" body lift to have more room, but it can be done without. 4 wheel drive?
Hydroboost is pretty easy. Just run your old high pressure line that went to the 6.5 pump to the high pressure cummins port, then make both returns go back into the reservoir. Some people get it to work with a T, I had to add another nipple onto the back of the res.

Look down the list in this section of the forums, there's been a couple recent threads. Maybe I'll throw up my pic collection later.

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this is most of my pics, not in order but a lot of ideas for ya

swap random pictures by oneillindustries2 - Photobucket

FastCR's Sig:

1995 Chevy K2500 Extended Cab Long Box P Pump 12 Valve + NV4500 + Military 37s
215s, No fuel plate, star wheel all in, WG shut, Southbend, stacks, some other stuff
'08 LMM 6" lift, 35's, blacked out, etc. (dads)
'02 VW Jetta TDI
I got a pocket full of bread a girl givin' me in the back row at the movies

Hey fastcr,
Thanks for the input.The tach problem was cured by using the chevy alt.The problem I am having now is getting a starter to fit.It is hitting the upper a-arm mount.I have moved the motor in several positions and can not get it to fit.

is your truck 4wd you could always go ahead and do a straight axle conversion while you are doin all this work

sidekick's Sig:

2006 Ram 2500 6" Fabtech lift, 35" Toyo Open Country M/T tires,
18" Xtreme Alloy 6001 wheels, S&B cold air intake and air horn,
Magna Flow 5" turbo back exhaust, Mads Electronics Smarty, Edge Juice w/Attitude,
Devils Own Water Meth, BD Super B Special Turbo, BD Boost Fooler, Trans and Converter by GOEREND , Home made traction bars

i'd have to disagree, i think the SAS wound up costing me as much, if not more, than the drivetrain when it was all done. Unless you have the cash to drop.
are you using a body lift? any way you can mount the motor higher in the frame?

If you check out AutoWorld MT, they sell the motor mounts to make it fit. You basically have to mount the engine a little higher to clear the A-Arm brackets. I also used their brackets to keep the GM alternator and GM A/C compressor to minimize wiring issues...

I just did a cummins swap into my '94. I have a detailed build over on pavementsucks dot com...I used a body lift because I wanted to make sure I had plenty of clearance for the tranny, and I'm glad I did.

If you are gonna stick with the IFS, you need to keep an eye on the ball joints. The IFS wasn't designed to hold the extra 600 lbs of weight that's going to come with the Cummins, not to mention the extra beef in the Allison transmission. I decided to go with a SAS Conversion myself, because I already had ball-joint issues with the 6.5 and 33" tires.