Engine/Transmission (1994 - 1998) Auto to Standard Conversion

[Hummin Cummins]

My auto transmission is living on borrowed time. I slipped the TC twice and and now babying it along. I would love to swap out the auto for a 5 or 6 speed, depending on what I can find.



I know the best route is to find a donor truck, but thats easier said than done. What I need to know is.....



Will parts from a 2500 or 3500 gasser work?



What changes in the electrical end will I need to do?



If I cant find a whole truck, what parts will I need to buy other than the transmission? I saw some NV4500s in the classifieds



Will my transfer case work? I know I will need to make driveshaft length adjustments.



Thanks

Chris

 

[Six_Man_Diesel]

I swaped trannies with cumminsgetme, I had the auto, he had the 5-speed. If I had it to do over again, I would have gone with a DTT automatic, as I am now going to have to rebuild the 5-speed soon, I already have $1200 in the project, by the time it is over, I will have $2200 dollars, could have got a DTT for $3000. I have no idea what all you will need for a 4x4, as ours are both 4x2. The only wiring we changed was the engine wiring harness, and the CPM. We changed nothing under the dash, or in the cab. Just ask if you need to know anything.



Willie

 

[Hummin Cummins]

My biggest concern right now is whether the small parts, i. e. clutch pedal, slave cylinder, etc. of a gasser will work. Its going to be difficult to find a diesel in the salvage yards around my area. I'm assuming that they are all the same on the dodges. I know I will need driveshaft adjustments, maybe a crossmember from a standard truck.



I just dont feel that the automatic is very driveable. It seems that it is next to impossible to maintain decent rpm ranges unless you actually shift the automatic like a standard transmission. Mine is constantly lugging. The only time it is decent is cruising on the highway. In town or on back roads where the speed limit is 45 or so, it is a major PITA.

 

[firemanmarc]

I completely agree with you hummin about the lousy auto. I see where after all the upgrades it is a good transmission, but why should we have to do that!!!! My 95 Powerstroke with ZF 5 speed was indestructable. Hauled just about everything you could imagine on the farm. Bought Dodge with auto so wife could drive(duh!). . Now am afraid to even hook up to gooseneck. Anyway I have everything needed for conversion EXCEPT for clutch to engine housing. You should not have problems finding clutch parts, the pedals will work from any 4X4 Dodge truck I believe!! Everyone told me I would need to change rear axle and transfer case, not true, only need to change input shaft on transfer case. I believe it will be a great project. Marc

 

[jimk]

conversion

I have been told the same thing about the transfer case by a fellow in Arizona about the input shaft. I would use a south bend clutch and a good pilot bearing. Do some thing with the 5 gear nut. I would get a transmission that is low miles and has is not abused, drag racing etc that you know of. The best in in my own opinion is a fully splined main shaft, is the best fix for the transmission.

LOL on the project Jim

 

[Hummin Cummins]

Any of you standard guys tell me what a good clutch costs? I'm tryin to make this a one time deal. I dont run hard, just back and forth to work and pull a 28' TT. I drive my truck pretty gentle. I always drive well over the speed limit when I can, but I dont push the truck hard to get to that speed. I really dont want to do this again. I knew what I was getting into when I bought the auto and started bombing, but I didnt think my driving style would do so much harm. I guess going easy on the soot pedal is worse for these trucks than mashing it hard. I assume that since I'm at the 120,000 mile mark that a full auto rebuild will be in order, so I'm tryin to weigh the $ to go either way with my transmission. I'm an old truck driver and I love jammin gears, but tryin to find a standard truck to buy is hard enough not to mention one from a salvage yard

 

[Extreme1]

A good T/C and a valve body kit will end the slippage. I slipped my stock T/C for a year before I upgraded, I haven't slipped the new one yet. Keep the fluid clean and avoid slipping until you can change the T/C. Aquick and effective fix would be to turn up the pressure a little as is.



I, too, considered a trans change but it would be better to pull all your goodies and reinstall them on the truck you really want.



The early upshifts are a "characteristic" of the '94-95's. I'm working on a good fix (linkage mod) but it's a ways down the list...

 

[Hummin Cummins]

I've been doing alot of reading on the auto upgrades and am heavily leaning toward a DTT VB and TC. I talked with Stefan a few times and am going to call an installer tomorrow just to get a ballpark figure. If I can nurse it along until income tax time, then I will make my move, at the high mileage I am at (120,000) will just these upgrades be enough? The rest of the transmission seems to work perfect and I have only slipped it twice. A full rebuild will probably be the way to go, but a little out of my budget.

 

[SRehberg]

Does the end of the crankshaft accept the pilot bearing without any mods? I know on some gas engines in earlier years, one set of cranks were for automatics, and then another for manual. I would hope the Cummins comes just one way, bored for both. Thanks

 

[98rammer]

hummin, a modified auto is very nice as i would chose it anyday over a manual. i've slipped my lock up clutch oh maybe 10 times, but i've been extremely careful lately not to. it's from 45-55mph is when i slip it if i ease into the throttle. so, i either *barely* move my right foot to accelerate, floor it (after letting off), or just simply run arund in 3rd locked. even with stock power, these stock autos are pos's