Gen 2 chevy 6bt conversion questions

[camsv3500]

Hi folks,,, Ive been here awhile but under my other name camsk5... . since thats gone and Im converting my v3500 Ive updated my signature

Ive had a Chevy to Cummins conversion thread going for awhile over at CK5 using bits and pieces from all sources



I am using a 1989 6bt for my conversion... its going into a super low mile chevy v3500 crewcab chassis



Currently I am disassembing the cummins for an inspection and rebuild



I intend to do the following pre conversion upgrades



1)Replace the factory springs with a 4 inch lift,,, using HD springs (I have superlifts on my reg cab v3500 truck and they are perfect in ride and strength so I was thinking of using those,,, with the cummins they will probably drop to 3 inch... or a modest lift



Im thinking of going all dodge drivetrain to eliminate some cross conversion hassles... I dont like the p30 adapter route and any other adapters th400/4L80/Allison are all one off customs without alot of road time to see if they will work out... While Im not afraid of making a one off custom adapter it seems like alot of work if I can make it all factory dodge

I was thinking of a gen 1 205 and a gen 1 or early 2 auto overdrive (properly upgraded)

As I gather those parts I wanted to make sure Im getting the right stuff (please provide input )



2) I have and will use an ORD 1 inch bodylift... this may allow the motor to be a tad higher in the chassis to avoid any oilpan/d60 front contact issues...



3) Radiator is unknown until I get it placed into the truck... I know there isnt a lot of room and its really hard to get the dodge fan in there,, Ive seen a number of conversion with electrical fans... maybe a mod to the front grill/radiator support will be necessary. . especially if I want to use an aftermarket intercooler



I just purchased the cummins manual... 65. 00 ... ouch... but it appears to be the only reliable game in town,,



A couple of conversion questions ...



4) my motor had the 727 on it... . does anyone happen to know if the adapter (drivers side starter) is the same engine side adapter on the 2 and 4 wheel drives. . and if this adapter is the same one used on the later first gen series dodge overdrives ( I want to know if I should hang onto it or not if I should go all dodge)



5) Any good reman tricks for the 47rh/205 version... and later re (stand alone kit?) if it still bolts to the 205(dodge pass drop).



6) Anyone know the differences (spline and adapter) between the 205 stick and 205 dodge auto transfer cases ... 29 vs 31 spline??? and IIRC there was some reading that the auto transfer cases twisted splines... . but this is all fuzzy old memory... anyone know?



I have a line on a gen 1 205 from a member here but its a stick case with no adapter... . are the adapters swappable b/t stick and auto cases... and are the cases retrofit possible ... or does the manual case have to be bored like old vs new big bearing chevy 205's (did I confuse anyone?) for the auto



6) Any good complete 6bt gen 1 overhaul kits out there... . the ones on ebay dont spec much and I might be afraid of getting one of those kits



thanks everyone... .



cam





ps... GO TIMO

 

[autoworld]

go look @ our website - all questions can be answered.

dawna

 

[camsv3500]

already been there. .



we will be talking in the future,,, you were already saved in my favorites



cam

 

[PKirby]

I had no clearance problems using a 1st gen. Dodge fan and shroud. The engine is set back as far as possible, I think approx. 1/4" from firewall.



My oil pan is larger than the Dodge pan but it clears the D60 axle because of my HD Rancho springs. I thought the weight of the Cummins compared to the old 6. 2 would lower the front but it didn't, those springs are stiff.

 

[camsv3500]

thanks mr kirby,, nice conversion btw... Ive followed your thread ... I like what youve done with the "duramix" radiator... Im interested how it cools and if youve had any post conversion hassles

What size bodylift did you use? 1 / 2 /or 3 inch...

I look forward to talking to you down the road... .





cam

 

[PKirby]

I used 1 hockey puck and 2 large flat washers per mount, around 1" total. It cools Ok no matter how I drive it. No problems towing or at commuting 80 mph on the interstate and 90 deg weather. The gauge stays between 180 and 190.

I had a new Horton electric clutch and fan available to use but I could not make it fit. It fit the 4 bolt bearing hub on a 4BT, and that was too tall. I also could not use the big fluid type damper that was on my UPS truck engine, the Dodge fan would not clear it.

 

[poor]

re chevrolet cummins conversion

i installed a 89 ctd in a 86 chevy 1 ton 2wd a year and a half a go i used the factory chevy 6. 2 radiator and trimmed the fan schroud to clear pulleys i made my own motor mount because i couldnt find any available at that time but frt and rear clearance is very limited but 6. 2 radaitor hasnt presented any heating issues also i just found a 81 1ton 4x4 crew chevy which is next on my list have two motors purchased for future conversions 91 w/od and a 95 out of a f800 w/ a eaton trans attached not sure of how many speed 5or6 i believe big bellhousing

 

[TBowles]

My 85 has about seven years on it and 100k miles with very little problems. Best thing i ever did Oo. ! No body lift is necessary and utilizing first gen a/c condenser, i/c, & radiator/shroud with a little trimming of the radiator support and it fit like factory. Will try to post pictures this week if the sun ever shines again. Also running 4 inch lift springs with ample oil pan clearance. Used cross member out of 4x4 dodge trimmed to fit between frame rails and about quarter inch clearance from firewall. About half inch deep by four inch long notch in passenger side frame rail to clear a/c with no ill effects (cracks etc. ) after 100k miles. Why some redneck has enough common sense to do this and Ford and Chevrolet were to stupid to pick up on it is beyond me.

 

[camsv3500]

yes. . pics please... thank you

 

[TBowles]

How in the crap does this picture thing work? i have the pictures on my computer but when i hit the add image icon on the post reply board it ask for the "enter text to be formatted" followed by (IMG xxx IMG). Does not want to let me copy and paste either. Any suggestions?

 

[TBowles]

Finally i think i have this thing mastered. Maybe?

 

[camsv3500]

motor pics...

Im having to resize all my pics to work on here...



PITA. .



motor is coming apart this weekend

thanks for the pictures... very nice truck and nice clean conversion





you didnt say what your running gear was. . stick or auto



cam

 

[TBowles]

Here are some more pics of the t/c, trans, & shifter linkage

 

[DWitcher]

What transmission are you using and is there not enough room to run the exhaust over the transfercase so you can run the front driveline?

 

[TBowles]

It's more of an issue with the cross member in the way than the exhaust as for as running the front drive shaft. I have aquired a first gen 205 t/c with adapter, 4x4 tailshaft housing & tailshaft. Just waiting for the right time to pull the trans and do the work. When this happens i will also run a new four inch exhaust straight down the passenger side of the truck. The trans is the stock 618 out of the wrecked 93 Dodge.

 

[poor]

chev conversion

that truck style is my next project i have and 86 reg cab chevy and it doesnt have a/c didnt think turbo would clear a/c box (my truck doesnt have a/c yet so i installed a low mount exhaust

 

[TBowles]

Pictures, Pictures I say. Oo.

 

[camsv3500]

I have a followup question... .



I have a 727 transmission that came with my cummins... mated to it. . it has the aluminum engine to transmission adapter... but its from a 2 wd truck... .



1) I want to use a later dodge EOD transmission. . maybe a 47h... will the original 2wd 727 adapter work ?



2) Does anyone know for certain which gen 1 205 I need to get to fit the auto... (they made two spline versions)... are the main shafts swappable if I find the "wrong" spline version?



3) Im in the market for the factory adapter... dodge auto to dodge 205... anyone have a line on one before I post elsewhere



Im electing to use a 3 inch lift... and perhaps 1 inch bodylift... to give me every last inch



Lastly. . I have an a/c truck... it looked to me as if it will clear the turbo... but be tight. . am I correct?



thanks "turbomen"



cam

 

[TBowles]

1. I think it will work with the first gen 618 but not with the second gen 47rh because the lock up t/c sticks out past the face of the trans further than the non-lock up.

2. You will need one from an automatic which I believe is 23 spline.

3. Check junk yards.

4. My three inch suspension lift worked perfect. Allowed me to lower the cummins down between the frame rails and line the radiator/fan shroud up just like factory with NO body lift.

5. I have 1. 5 - 2 inches clearance between the turbo housing and the evaporator/heater core housing which is plenty. That is with the engine centered up in the frame NOT offset. I put up some heat resistant material in that area just as insurance.

 

[camsv3500]

ok. . so if you wanted to use a 47rh . . does that adapter bolt up to a 205 or did DC go to a different t/c at that point





thansk for the info all



cam