99 chevy 2500 4x4 recieving a 5.9 transplant
 

Hi guys,
We are getting a fun project at our shop! We are going to make a step in the right direction by amputating a 6.5 td from this Chevy truck. The organ doner is a 96 Cummins 5.9. We are looking at a Allison 535 or a 545 trans for this project. Problem may include tranfer case to trans mounting. Any one done one? We will keep y'all posted from time to time.
Any pitfalls we can avoid because of prior trial and error by y'all would make this much more fun for us and y'all. That way we can all gain some smarts and get better at what we do best.....makin smoke.

if you've got room, just divorce-mount the trans/t-case and get appropriate-length drive shafts. that ought to simplify at least one aspect of the job pretty nicely:pca1:

Re: 99 chevy 2500 4x4 recieving a 5.9 transplant
 

If your going with the big trans, devorce mounted seems like the only way to go. Devorced 205s are cheap and gear drive. They can be run way clocked.
Get the autoworld mounts if your keeping it ifs.

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transplant
 

As things go, so goes this. We need help with a charge air cooler for this beast. What fits close and doesn't require days of modification to get it in correctly? Performance Radiators has coolers for D-max and everything else but I know there is some genius that has already solved this challenge. Any guided direction would be greatly appreciated.
As we progress we will send pics and info.
Thanks diddydoc2

most people i know use a 24 valve cummins IC. Basically get the IC, a summit aluminum radiator that fits in it, take off the grille, take out the radiator, and start cutting until it fits. you have to trim the headlight adjusters iirc. Its very possible but you just have to get it together and start cutting until it fits, when you hold it up to the front of the truck it just looks like there's no way. I think autoworld includes some instructions with the mounts on how to make it work as well.

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I have a dmax IC and it basically won't work. the body mounts and front of the chassis would have to be really modified to get it to sit low enough to clear the hood.

you can use the chevy or 2nd gen dodge radiator, either the 2nd gen dodge intercooler or a ford superduty will work, you will have to trim the headlight mounts for them to fit. on the motor mounts autoworld, destroked and others make them, or you can make them yourself