95 Gas to 91 cummins

[Ky Trash]

I have 95 2500 4/4 5speed gas also have 91 diesel auto 2wheel. Want to put the cummins in the 95. All help appreictaed.





Thanks.



















t

 

[DKarvwnaris]

I have 95 2500 4/4 5speed gas also have 91 diesel auto 2wheel. Want to put the cummins in the 95. All help appreictaed.





Thanks.







t

Without a donor truck of the similar body style, I would not do it. The engine will go in jusgt fine, but you'll need to update the mounts, dash, ecm etc. for everything to work as factory. If you don't care about that, then just drop it in and run it. You'll be better off buying new motor mounts from Dodge or cummins for the older 5. 9. Expect an easy repower compared to some, but don't think its going to be a cake walk either.

Personally, I think you'd be better off selling the 5. 9 engine and the gasser truck, then go find a suitable dodge diesel already factory equipped.

 

[DPinkston]

If you are anywhere near Lebanon Ky I could give you a hand, or at least some tips (not fingertips though :-laf ).

Danny

 

[Ky Trash]

Thanks, Danny I need all the information,I can get about making this swap. I have a friend,who works at a dodge dealership nearby. He says the bellhousing,imput shaft, mainshaft, slave cylinder assemby,radiator,are different in diesel. I want to keep the 5 speed. I have the radiator,imputshaft,mainshaft,clutch,flywheel, and pressure plate. I don,t know if I need to use the ecm from the gasser or the 91, can get ecm from a 96. how will I wire the diesel to start,shutoff?Thanks for any info. Joe

 

[Ky Trash]

Sorry I forgot,I live in the Somerset area,Joe

 

[DPinkston]

Thanks, Danny I need all the information,I can get about making this swap. I have a friend,who works at a dodge dealership nearby. He says the bellhousing,imput shaft, mainshaft, slave cylinder assemby,radiator,are different in diesel. I want to keep the 5 speed. I have the radiator,imputshaft,mainshaft,clutch,flywheel, and pressure plate. I don,t know if I need to use the ecm from the gasser or the 91, can get ecm from a 96. how will I wire the diesel to start,shutoff?Thanks for any info. Joe

As I understand it, the only thing the computer controls on pre-98. 5 diesels is the alternator, cruise, tach, and grid heater. You can't use the ECM from a gasser to run these items. You'd have to use the diesel ECM. I'm only familiar with the P7100 pump fuel shutoff solenoid and it was easy enough to wire up using a relay. If you have access to the whole donor truck there shouldn't be a big deal. Sounds like you might need to get a diesel trans though. You could probably sell your current trans to offset the cost.

Danny

 

[DKarvwnaris]

You will need a diesel ecm if you want to have everything work as normal in a 95 diesel. The older rotary pumps require nothing more than 12 volt power on two connectors to make them work. Starting requirements for the older 5. 9 is just a set of grid heater solenoids and a heavier set of battery cables to handle the amps of the denso diesel starters.

The diesel nv-4500 in the dodge has the largest input shaft of all nv-4500's. The gas transmission will work so long as you have a v-10 engine, you'll just need to change the input shaft for this. Not a big deal, it unbolts and slides out of the front of the transmission with no real mechanical skills involved. Only concern in swapping the input is making sure you only apply enough sealant to seal the flange, too much will plug the oil port and run the outer input shaft bearing dry.

If you have a friend at a dealership that can provide schematics and parts diagrams, you have little to worry about. Most of the factory harness has the plugs in it to just buy the neccessary diesel electrical parts and connect them straight in. I would really suggest finding a junker to pull the entire harness out rather than buy each part new. Depends on much understanding you have for electrical verses how much money you have to spend.

For about $100 you can make everything you need to deal with the electrical side of the conversion. An older 93 dodge voltage regulator will take care of the alternator regulating issue without messing around with a newer ecm from a diesel. (easier and cheaper to replace too). If you have the regulator in the older truck still, I would just use it. This eliminates middle of the night breakdowns or weekends at a hotel while you wait for an ecm just to fix a unregulated alternator. (this happened to me in my 96 recently, it is now equipped with a 93 voltage regulator which I can find anywhere now.

I'm not around here much anymore as my busy season has started for work. If you have questions you can't get answered from others here, drop me an email.

What you want to do is not hard, just time consuming. You'll be facing a small appraisal value if something should happen like an accident that totals the truck, or a theft altogether. If you wish to go ahead, I have done several of these for people before who bought 98 and newer trucks to gain the quad cab doors and still get a 12 valve engine. A few were gas, and a few were 24 valve equipped, the gassers just took more time to deal with gauges, fuel tanks etc. No real difference than that.

Good luck in your plans.

 

[Ky Trash]

Thanks for the info guys,you two have anwsered alot of my questions. I hope to get started in the next few weeks.

 

[Ky Trash]

Getting started

I changed my instrument cluster today,started to change heater control panel found out no place in the gaser wiring harness. when to wrecking yard found a 95 diesel. the small harness to the wiat to start light,etc. is wiring from factory,case pocket knife safed the day. Now i have to wire it in. Stay tune for more.

 

[DKarvwnaris]

I changed my instrument cluster today,started to change heater control panel found out no place in the gaser wiring harness. when to wrecking yard found a 95 diesel. the small harness to the wiat to start light,etc. is wiring from factory,case pocket knife safed the day. Now i have to wire it in. Stay tune for more.

Pocket knife?!!! Why would you cut the harness apart? Remove the entire harness from the interior of the truck, it will give you all the connectors you'll need for the diesel electrical, also the ECM etc.

Removing the harness from the diesel cab isn't a big deal, the dash in the dodge trucks comes out in about 20 minutes with a few screws and grounding nuts. I have pulled them out in wrecking yards with no problems many times. It saves you going back and keeps the wiring issue minimal for alterations.

 

[Ky Trash]

Yea your right i should have got the harness. I screwed up,but the guy cut harness and bought it back like that. I plan on keeping this truck for years to come. Been hard to find,junked diesels around here. Start looking again monday. thanks for your input.

 

[towner]

I have a 98 nv4500 input shaft and collar... . $50 and its yours... . I put a chevy input for my FJ40 conversion

 

[DKarvwnaris]

I have a 98 nv4500 input shaft and collar... . $50 and its yours... . I put a chevy input for my FJ40 conversion

This a really good deal, if you don't have the input shaft taken care yet, jump on this.

 

[Ky Trash]

Thanks but I have a new imput shaft already. I also have another nv 4500 case,How do I tell the different between a chevy case and a dodge case?

 

[Ky Trash]

Getting started again.

I finally found a dash wiring harness today. My son has had back surgery,two weeks ago,dad has been playing nurse. He's getting around on his own now,so dad can go back to work now. I have found a 24 vavle with a 12 vavle pump. Should I buy this motor and use it?