auto to manual swap
 

well me and dieseldocter16 under went the g56 swap in my 04 cummins. heres the do's and donts of the swap. i got a g56 with tcase from rondo enterprises and the clutch from tony at mighty diesel. started off with all the auto trans parts removed ie the cables lines harness and little other stuff out, installed the new clutch and flywheel, and hydro's. then after much fighting with junk jacks we installed the trans you must cut the hole in the floor to the size of the larger stamping that is visable via the underside with the insulation. we then installed the trans and then the tcase and cross member then the drive shafts , i have a quadcab long bed the rear drive shaft will work with no mods but could be 1 inch shorter so im gona have it cut down the front shaft will work but should be 1 inch longer to keep them at stock lengths. the crossmember will work with no mods. the steering column will work just remove the shifter and wiring key will go in and out no problem and steering will not lock. the auto cup holder must go. now for the pedals the bracket is the same auto and manual the hole and area for the clutch pedal is there, just install the pedal and pins and cut the brake pedal to size and your done. hook up the hydro's to the pedal and trans. im waiting for my tuner to come back to reflash the truck into thinking its stick but till then im wiring up a push to start switch. the abs is not affected at all by the swap, so heres my parts list

trans
tcase or the input gear
clutch and hydro's {dont forget the retainer for the clutch master cylinder}
clutch pedal
shifter
cuphold/ console
starter button or programer to reflash truck

ill be posting pics soon hope this helps

looking forward to seeing some pics :U:

The G56 is sexy. Cant wait to see how it rips. :choochoo: :rocking:

I would like to see some pics.Why did you swap?Could you not find a auto to hold up/Just curious i have a auto.Damn 5-7 thousands alot of money for a billet tranny.I am almost at the point you are at.

thats good redsled:U:

pics are coming....... the swap ran me 4800 bucks i did the swap because i miss shifting and auto wasnt cuttin it

cool! :U:

The truck also sounds 10 times better now that it's stick. :U: :choochoo:

i am doing this swap on my truck and i found the g56 tranny,tcase,clutch,flywheel,hydros, pedals, tranny plate, and driveshafts out of an 06 dodge. Do you think these will bolt up to my 04 truck without any problems?

i figured everyone would be going with a nv4500 nv 5600 beings the alloy case on the g56 is the weak link when i changed my cluutch 50 k i noticed my imput shaft has all kinds of slop in it did some talking with south bend and blumenthaw transmission and both said its been a pretty common thing on the g56 and the 4th gear probs i have heard of a few and a guy i know blew 4th out of his $1800 just to fix what needed to be to get him by but i did get word of a cast housing is in the making for the g56 then it will be a tank i think im listening ears here though :c:

g56 will bolt up to any of the common rails, you only need the pedal pins and hydros the bracket is there for them just swap brake pedal and pop in the clutch pedal, as far as the strength goes both me and my dad use g56's we are hard on them and they take it all , learning how to launch and how to run the trans is key also braces are made for them now. the trans plate should not be needed i use my auto bell no problem , loop ur N safety , and get a reflash and your good

Thanks for the help!! If I get a g56 will my tranfercase bolt up if I change the input shaft?

yup just get the right one

07redsled. Do you know who makes the braces for a g56? Or do guys make them themselfs?

I'm swapping one in right now from a 2009 cummins into my 2003 cummins, just curious if there's any thing other then the smarty reflash you have to do for wiring? I want cruise to work and I've read that the horn will honk if its running and you open the door,I just want it to be normal, any info will help

the horn honk will be cured by the reflash , cruise will work no matter what , ie it work even befor i reflashed it , pin the nutral safety in N thats all

and as far as the brace goes lazersmith makes a gorilla brace, i make one too just only running them on my truck and my dads so far

I have a steering column from a manual truck I'm putting in with it, will that complicate the neutral issue? Also how do you get the reverse lights to work?

id skip the column, run power to one side of R switch run wire to reverse light wire tap in and you got reverse light

I got a heap of parts from an 06 mega cab for the swap, interior don't matched (figured it wouldn't) should pedals work? I didn't think they changed that but I could be wrong, also I read about connecting the #3 and #5 wires together on the 5 plug auto tranny harness, what's that about? I have a lot of un answered questions about the wiring stuff but other then that its almost done:humm:

Saw the one that lazarsmith makes. Nice lookin unit, a bit pricey. Looks like it would act as a brace, shroud and clutch scatter sheild. I was thinkin something that mounts from the bell bolts to pto covers and then gusset it.

Just got it all done basically, everything worked right without reflash, except honking when doors open, southbend dd shifts awesome, still need interior console(s) but its in the mail and a shift knob(my b&m t-handle is sae, threads metric) airdogs hooked up as well next exhaust turbo injectors headstuds, looks like a brand new truck:)

good to hear man enjoy its great to know your trans aint gonna slip and fail

Good to hear!
So after a reflash, you will be able to start the truck with a key instead of a button right?
And do you have any pictures of the swap?

Just some of the trannys moving in and out and t case going back up, nothing to specific, I didn't realize how easy this would be, once you get the g56 and t case with drivelines in, its a breeze from there, I owe a lot of thanks to Tim Mckenzie at Diesel Xtreme in billings montana

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Also I never needed a button for it, it start fine and dangerously without anything special, now that the neutral safety switch is hooked up you need clutch in to start it

Ok so you were able to bolt the 56 straight top the 48re tranny adapter?
No need for a g56 adapter? And where you able to use the same starter?

Ya, cummins adapters are all the same really, we used a 2009 g56 that was connected to a 6.7, it bolted up no problem, starters the same too

Good info, also did you end up switching the steering column or just the column covers?
If you switched the whole column, do that mean that you had to use a different ignition key, or can you put your old ignition on the new column?
And just wondering, where did you get all your parts from?

No we didn't switch columns, it was more work then it was worth, we switch covers though, pedals and cover came from a wreck 06 mega cab tim had in the lot, clutch and hydralics were all with the southbend dd, tranny came from spokane, order t case shaft and only lengthened rear driveline, interior pieces we ordered from our dodge dealer, connected the number 3 and 5 wires from the 5 pin auto tranny plug to neutral safety switch, hardest part so far is try to sell the auto stuff

Do i need an engine adapter to from to go from the 48re to g56?
Or can I use the one I have?
What about the starter, can i use my original?

Starter and adapter are the same, you can use the ones you already have

And one more question, I have the 48re, did you have the 47re or the 48?
My auto trans range sensor plug is a six pin, am i looking at the wrong one?

6 pins 5 wires #3 not used

Oh ok I see, so then I am actually connecting the wires in position 4 and 6, even though they are the 3rd and 5th wires?

its a multiplex range sensor , get a nss switch from auto store or stealer ship or off the old auto pin it to N or P

One more question!
I started disassembling after work yesterday, and just want to make sure after the swap, with proper Smarty manual programming, that I will still be able to pass smog when they hook up to my OBDII port.

you should pass even with out the program

Ok so I still haven't reflashed my truck and 2 weeks ago I did a sled pull and in 4 low and 3rd gear the tires don't spin fast enough to register wheel speed and it cut fuel off at 2600 rpm, needless to say I got a pathetic pull, and I've now tried the flash file from GOS and the one that bob wagner himself sent me, neither one of them worked on my truck. Probably gonna take it to the dealer tomorrow cause there's another pull tomorrow night, let me know if there's something else I can do

i know lazar smith makes the braces

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wow just realized this had 3 pages sorry for a late post:argh:

ok as far as the defuel goes i have played around with it on my 04, it doesnt defuel on me when i have the N range sensor in D also i found that the tst seems to make the defuel go away i dont know how but if i remove it truck fuel cuts at around 2500 tst hooked up it fuels hard to bout 3400 oh and 03pcuminsr pm sent

I didn't use the transmission range sensor on my swap, I wired the plug that goes to it, to the neutral safety switch on the clutch pedal, that may help you out.