Chevy Z71 6BT Swap Plus- completed
 

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...

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

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

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

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

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I ditched the small temp filter and made my own intake tube with bigger filter.
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Ran into a problem with a rotted freeze out plug. I replaced them all with a billit set.
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Truck as it sits.
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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.