Engine/Transmission (1994 - 1998) 12 valve conversion with lots of questions...

[RyanB]

Hey All-



I am posting this in both this forum and the conversion forum because its been kinda dead over there for the last while so here it goes... .



I have a 1989 GMC 1-ton reg-cab 2wd Dually. I am in the process of doing a major conversion with all the best parts!!!!

I am dropping in a 1996 12-valve (215hp) into the truck with a NV5600 behind it with a NP241HD T-case (Yes I am also converting it to 4wd) I am also putting in a Dodge Dana60. (OKAY... . I know this isn't the axle of choice... . I would have went with a Ford Dana60 any day but I am going with the coil springs seeing I have the 2wd frame). As for the front suspension amazingly it should all fit together great. I am using the GMC coils which are smaller in diameter and 4" shorter because the dodge coils would hardly fit into the pockets and gave me way to much lift!!! In the rear I am going with an AAC 11. 5" out of a 2004 GMC dually. I chose that axle over the Dodge AAC over the Dana80 because it is said to be a tougher axle and has a much better posi in it seeing the selection of lockers are still limited.



Here is the rundown of the cost of parts that I am using and I think I got a really good deal and all the drivetrain is rebuilt with 6 months/10,000 miles warranty.



$3000cdn - 1996 Cummins 12-valve (215hp)

(3months/5000miles warranty



$3000cdn - 2003 NV5600

$1000cdn - 2000 241HD t-case

$1500cdn - 1997 Dodge Dana60 (dually) with

the suspension parts

$2000cdn - 2004 GMC 11. 5" AAC (dually)

$500cdn -front and rear drive shafts

________

$11,000cdn =$7,998US



I thought it was a pretty good price. Anyway, here is my question. It will be almost the begining of Sept before I get the truck on the road. I am looking or was looking to bomb it right from the start to about 450-500hp. I also live up in Ontario, Canada and have real winters!!!! should I wait till the spring to do the bombs? what should I do now? I was planning on an ATS manifold and HX40 turbo and of course an SBC (probably the new FEW). If I were to run these 3 on the stock engine would it effect anything? then in the spring I will put in a good plate, big injectors. What all am I going to need to get a 215 pump to 500hp? I am getting the head O-Ringed before I install the engine!!!.



Does anyone else have anything other idea's on things to install while I have everything apart (engine or other wise)???



Thanks in advance... . Ryan

 

[RBratby]

i would do the kdp if it hasnt been done already. i would install 370's 191 dv's and a #10 plate to give you a good start. the hx40 on a stock engine will spool slow but that is about it. the clutch and ats manifold are fine to run on a stock truck. you will need gauges on this truck with the power you want to run. i would also get gsk's too.

 

[RyanB]

What is it like to go into the pump? would it be alot easier to just go in and do it now or could I wait till the spring? Also, those of you making good power and live in the snow belt... . how is the driving for you in the winter? I just don't want to be spinning the tires non stop all winter.



Can anyone give me list of mods that will get me up to the 500hp range with the 215HP pump? I am also going with 4" straight piped thru duals if that makes much of a difference. As far as guages... what does everyone recomend?



Thanks again... Ryan

 

[RBratby]

if you are going to run a 500hp truck in the winter and are worried about it spinning the tires then install a valet switch. the gauge are up to you pick the ones you like. everybody like different gauges not for guality reasons but for looks or design.

 

[RyanB]

Okay, you lost me on the valet switch? how is that possible on a 12-valve motor? or do you mean a 24 valve? I have read tons about 12 valve mods and never heard this mentioned!!



Thanks. . Ryan

 

[RBratby]

you install a valet switch on the 12v not 24v. i would contact rob thomas he can install them or ask the very knowledgable people on tdr to help you there are people on here that have them. i dont have 500hp so i dont need one thats why i dont know how to put them in.

 

[RyanB]

Okay, what exactly does this switch do? I totally never remember hearing about this being done.



Ryan

 

[JoshPeters]

Ryan,

My valet switch is hooked up between the AFC housing and the boost "signal" line from the intake. With the switch actuated it blocks off the pressure going to the AFC, that way it doesn't give you full fuel. Mine works great... if I had to guess I'm at about 370RWHP, and with the switch actuated I'm just better than stock as far as seat of the pants feel goes.

The valve I have is an EGR control valve for a Mercedes-Benz. I think customer cost is like $35 on the valve. $3 for the switch and wire. It's an easy install. If you'd like I can get you a part number for the valve.



Josh

 

[Woodenhead]

Ryan



Where in Ontario are you from, I'm from Woodstock. Can't help you much on the Valet Switch (don't have one). Don't worry about driving in the snow with higher hp, I've never had a problem. Like anything else you just have to be smart with the right foot and know your rig. As far as hp goes here are my Dyno results with the mods I have in my sig. I'm told a little plate tuning will give me a few more hp and I can always crank up the H20/Meth to 200 psi for some more occasional ponies.



Take it easy eh!

Mike

 

[RyanB]

Woodenhead-



Im from just north west of Waterloo. Not to far at all from you!!! Will have to stop by some time on my way down to Long Point bass fishing!



As far as this switch goes... . Sounds like a great idea and after searching for a while I now know how it works. Does anyone know what the name of the kit is that Piers has? is it the "preformance switch"???



Thanks again... Ryan

 

[JoshPeters]

Mercedes-Benz part number is: 001-540-86-97. Retail price $32. 50us.



Josh

 

[Woodenhead]

Nice to see a member close to home. I spend 95% of my time working on the road so I don't get home much. Got a few friends over your way, mainly in Cambrige (Newfies ). I grew up fishing and camping at Longpoint every summer back when the Bass fishing was much better. Use to catch some monster Northerns also. If I make it home for any period of time I wouldn't mind checking out that Shovey project though.



Why a do the transplant in a reg. cab Chev? If you're going through the trouble why not find a crew cab and have the best of both worlds. Just a thought.



Mike

 

[RyanB]

Woodenhead-



I thought long and hard about the whole crew-cab idea and the reason I am not going with it (for now!!!) is the extra weight will put me over 8000LBS for all the pulls up here and also right now I don't need the room and I also love the looks of a reg-cab dually!!!!! In the future once I have kids I am probably going to lengthen the frame and make it a crew cab but if I do go to all those hassels of lengthening the frame I think I will do a custom 6-door crew-cab!!!! That will probably be in the works within the next 3 years.



As for fishing at long point... . There are some big ones in there still. Last year I cought a 6lbs large mouth, a 5 lbs smallie and a 15lbs northern.



I take it you drive truck huh? if so who do you drive for???



Ryan

 

[JO'Leary]

Ryan, I too was going to swap in a 12V in a 94 Chevy, been a GM man all my life. I got severall replys that said just buy a Dodge with one in it already. After putting together prices and figuring in my time i said what the heck. Sold the Chevy and found a 98 12V for just over $10k US.

Best truck i have ever had. Keep us informed and good luck with the swap.

Joe

 

[Woodenhead]

Ryan,



No truck driving here. I work on Hydroelectric Generators so I spend most of my time in Hydro Dams all over Canada and US. The company flies me wherever I need to go but sometimes I drive (paid mileage) just because I like to drive. In the past 2 years I've driven out to Washington state 3 times, up to Drayton Valley Alberta (from Wa) back down through Wa. out to North Carolina and on and on and on. Maybe I shoulda been a truck driver.



Can't blame ya for wanting a reg cab, often wish I had a full crew but hey... to each his own. That's quite the ambitious project, must be nice to have a little spare time for these things.



Mike

 

[SMorneau]

Ryan, 500 hp in a two wheel drive std cab dually? Are you are going to have some serious fun?



You will need a good clutch. Do your research on turbos and consider doing your pump mods and other things later after your sure everything is working correctly. If you have the time it would be a shame to skip over all the rushes you get increasing your hp a little at a time



The 96 215hp is a nice start.

 

[RyanB]

SMorneau- It was a 2wd but I am converting it over to 4wd right now. It really hasn't been that hard so far and I only have 4 hours into it and its almost done. The hardest part is doing the homework before I started and to make sure it all would work. I am shooting for 450-500hp and as far as a clutch Im not sure yet what I am going to go with. I was thinking about the new SBC FEW but then I am also thinking of the Enterprise dual disk!!!!!



Ryan

 

[TPCDrafting]

While you've got the head off, put on the HD valve springs intake and exhaust. (Yes another call to Piers) That way you can put in the 4k gsk. The spring kit must be easier to do while the motor is out of the truck. Sounds like a big project.