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

 

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

 

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.

 

I dont know if you figured out the hydro boost situation but the stock gm ps pump will adapt to the dodge. You need to get rid of the vacuum pump housing on the dodge and replace it with a one off of a truck that was running hydro boost. Then take your stock ps pump from the chevy and remove the pully and adapt the dodge pump parts so you can bolt the chevy pump to the dodge motor. sounds confusing but it works. I just did it on my truck.

 

Thanks for your input A-prius. I did the p/s as fastcr stated above and it has worked perfectly. This swap took me six days to comlete and under $3,000 including motor and trans. I have clocked over 30,000 miles since with NO problems. The one thing that I am still having trouble with is an intercooler. Everything is so tight. I thought about mounting it under the bed, But routing two 3" pipes past the motor and trans will be difficult. If anybody has any ideas (besides water/methanol inj.) I am all ears.
Thank you to all for your ideas and input.