Another 1st Gen rebuild

[Andy314]

I have a 92' D350 1st Gen. I also have a 79' W200 Power Wagon. I am considering putting the Cummins into the 79. I am slowly realizing the issues such as the trans and transfer case in the 79' may not be the best, if they will work at all with the Cummins.. Also since my 92' is a 2wheel drive, the computer and wiring may not support the 4X4.. Short of finding a wrecked diesel 4X4 cheap for a donor. Does anyone know of a place to order a wiring harness for a 1st Gen 4X4?? Painless wiring is a good generic source, but I would rather have the original.

 

[RWherley]

The only electronics that go with the 4X4 system is the light on the dash that tells you that your in 4wd and that's turned on by a switch on the transfer case. but the gas transmission will not work with the cummins.

 

[Simplysmn]

your 2 wheel drive harness will work fine and Everything plug's into place if you use the 93 dash then it is all Plug n Play on the swap . you need any advise send me a PM .

Val

 

[Andy314]

The only electronics that go with the 4X4 system is the light on the dash that tells you that your in 4wd and that's turned on by a switch on the transfer case. but the gas transmission will not work with the cummins.

Thanks for the reply. I am having to look for a trans.. Any thing you can think of I should keep in mind?? I more than likely will go through the trans prior to install.

 

[dodgenstein]

The 203 full time transfer case probably won't hold up to Cummins torque either. The W200 usually has a Dana 44/Dana 60 axle combo that won't live long either.

 

[DVolk]

It will work but the splines wont work on the 203 , if nothing else use a 2wd trans and a divorced 205 watch craigs list transmission are out there

 

[RWherley]

I don't know how much work you want to do and if your truck dose have the 44 / 60 axle combo. But I do know of a gas powered W350 SRW here in Gettysburg with the Dana 60 front and 70 rear axles on it as well as 23 spline NP205 transfer case if you are going to use an auto transmission in your truck.

 

[Andy314]

I don't know how much work you want to do and if your truck dose have the 44 / 60 axle combo. But I do know of a gas powered W350 SRW here in Gettysburg with the Dana 60 front and 70 rear axles on it as well as 23 spline NP205 transfer case if you are going to use an auto transmission in your truck.

Well I don't know how much work I am getting into.. I know it will be more than a weekend project.. I just divorced the 79' power wagon idea all together. I found a 92' extended cab dually 4X4, someone pulled the Cummins out to put it in a Chevy?? I ask why also!! Anyway, he claims the frame is shot on the dually, so I bought everything. it has a getrag g360 5 speed, only he kept the bell housing. so I'll have to find that, but other than engine and bell housing it's a complete truck.. So I am going to check out the frame, then decide whether to build the extended cab or regular cab.. I have to keep the 8ft bed. Then it will be sell off the excess parts..

 

[Andy314]

Also one more question.. When going from the automatic transmission to the 5 speed, do I need to change the fly wheel? I know a lot of the gassers I've worked on have flex plates with the manual trans..

 

[RWherley]

Yes you will have to change them out, the auto has a flex plate not a flywheel. It will be easier to build a truck that is already set up as a 4x4 but 2wd to 4wd is not that hard to if you have the right parts and tools, When I did my 4x4 conversion it took me about 11 days to do it my driveway. That includes fully rebuilding the front axle before installing.

 

[RWherley]

If you had your heart set on a diesel Power Wagon you just put the power wagon sheet metal on your 92 drive train.

 

[HHhuntitall]

I think you're missing some details here... your power wagon can have a variety of combinations of parts on it... you need to identify them to see how they'll work... and an 8 lug Dana44 axle is not the best, but with a moderate powered Cummins, it will hold up fairly well, depending on how you use it... And there are numerous Power Wagons made that had the Dana 60 and NP205.. it all depended on how they were ordered. The splines won't match up with the gasser transmission, but there are collars available that go in the front of the T-case to make it work with the diesel transmission.... The gasser transmission won't work, but there are other transmission options out there... As for wire loom, it again depends on your Power wagons options and what you want... Does your PW have AC? Do you want that feature with the Cummins engine? Do you want to do a little wiring?

IF you want to keep the factory PW wireloom, just run the coil wires to the fuel shutoff solenoid, and the alternator wires will work as they are, depending on how you route them.. they may need a little extending. Same for the AC compressor, if your existing wire loom has it. The only thing different is the grid heaters, fuel heater, and Water in fuel light, which can easily be rewired on relays to work....

If you want to use the '92 wire loom, the Dash from the '92 will bolt almost directly in the cab (I think the 79 fits perfectly, there were some differences in '76 and earlier trucks, IIRC) and you can use your factory wire loom....

Also, your fuel lines will come in to the engine compartment on the passenger side on the PW, but the diesels came up to the driver side... all easy fixes, IMO. It just takes time, but you realize that, obviously.....

 

[DVolk]

Id watch the Getrag , He probally left it in there because it was junk

 

[Andy314]

Ok so I have a 1992 D350(was my Dads) was a dually, now a single wheel rear. I have a 1992 W350 extended cab dually complete minus the engine. I am planning to pull the Cummins and put it on the W350 frame. I am considering converting the W350 to single wheel rear for several reasons. 1. I don't tow heavy loads requiring the dually. 2. Cost of two less tires is appealing. 3. And the dually rear has 188,000 miles, no clue the condition of the brakes, bearings, seals... the single wheel rear I had complete gone through around 1500 miles ago. From what I can see right now the gear ratios are the same.. The conversion of the D350 front end to the single wheel set up was pretty simple. How easy is the front diff of the W350 to convert to take the single wheel set up?? Waiting on the to get better to get started! signed, Too Poor for a Garage!! :{

 

[RWherley]

It's pretty much the same as converting the 2wd front end to a single wheel you just need to get a different set of wheel hubs and put them on the axle.

 

[Andy314]

It's pretty much the same as converting the 2wd front end to a single wheel you just need to get a different set of wheel hubs and put them on the axle.[/QUOTE

That's the answer I wanted to hear.. Thanks

 

[HHhuntitall]

... except the single wheel hubs are available, still.... Ever tried to find a set of 4wd dually hubs? What do you want for them? I may be interested......

 

[DVolk]

The gm dually hubs will fit so will a ford if from a dana 60 , i got a chevy set , or you can buy the adapter that works as well

 

[HHhuntitall]

If you go GM, you can keep your outer axle shafts... if you go with a Ford one, you'll have to change your outer spindle and axle shafts. Ford's are longer.

Quad 4x4 has them, but I'm not sure of pricing. They're usually higher'n Willie Nelson in an elevator, but usually have it and will stand behind it. Out of curiosity, I looked on Ebay, and there are several sets there for less than $400..... The boneyards will have them, but be careful, as the internally splined hub is from 90.5 to 93, and the outer drilled hub (with eight bolts, like your rear end) is from 90.5 and earlier, which uses they Selectro locking hub. I guess if it works, do you care?

 

[Andy314]

... except the single wheel hubs are available, still.... Ever tried to find a set of 4wd dually hubs? What do you want for them? I may be interested......

I haven't even the slightest idea.. What are they worth?