How much work,and other questions?

[mazdarotary]

Hey guys,



I was wondering how tough on a scale from 1-10,10 being hardest it is to do a swap of a Cummins to a crew cab is. Also I was wondering aside from the cost of getting both the Cummins donor,and a crew cab,what am I looking at spending for a project like this?I already have a 92 D250 that doesn't seem to want to leave my yard so that is half the battle,and I have found a nice crew cab via this site that I could get for a few thousand dollars. So what will it cost to do the swap,and can it be done in a few weekends,with some help?I am thinking about this option as it is what I wanted to do in the first place anyway,but I went,and bought an 03 1500 hemi quad cab which is a nice truck,but it pales in comparison to my tried,and true diesel. I am thinking maybe I could get the crew cab,and do the swap,and then when it is done sell the Hemi which may or may not sell easier than my 92 D250. Is this a feasable swap at around $5K with the purchase of a crew cab at around the $3K mark,and a complete 92 D250 with a NV4500,recently rebuilt rear Dana 70,and otherwise in good shape?Also I was wondering if it is a straight swap from the dual axle of the crew cab now to my 3/4 ton single wheel axle,and bed?How about the fuel tank/s from my 92 (with transfer-flo tank in place of spare tire),will they bolt right in place on the older 85 frame?Thanks for listening to all my questions. Oh yeah I have a garage but it is a little undersized,and full of vehicles at the moment. Also feel free to tell me I am nuts for wanting my old noisy diesel over a newer quad cab truck,maybe the creature comforts of the new one are nice,and maybe safer for my growing family,but I would rather have the old truck with low,or no payments than the new with moderate payments. Thanks again.



Chris

 

[bgilbert]

If the crew is a dually, you could use the D60 dually for awhile if you don't tow too heavy and don't bomb the engine. If you want a D70 and SRW, you're gonna have to swap the beds. But then the front hubs would need attended to from what I understand. You'd have D350 instead of D250 hubs. Everything is mostly bolt up. I *think* driveshafts build will be the most expensive. The rest is all switch over and bolt up. You could even use the gasser fuel tank if you built a 1/2" fuel pickup with bulkhead fittings in the tank to the lift pump. Thats how CKnoop did it and I plan to do my crew.



I think you'd easily get it done under $5k. I say you're only gonna be out for the crew purchase and then the preventitive maintaince items once the engine comes out - front, rear main seals, clutch, new radiator what have you etc.

 

[mazdarotary]

Thanks Bill for the reply. You are saying that because the dually has the spindles that stickout further for the dually wheels that I would need to swap them over to a normal 3/4 ton spindle?I was thinking about the swap over to my axle mainly because I don't need/want a dually while having ths 40' long truck. I really only need the capacity of a half ton most of the time,but I love my Cummins,and I already have it stting in my yard. Would it look wierd or drive funny with the dually spindles up front,and my 3/4 ton Dana 70 in the rear?



As far as maintinence stuff during the swap,I replaced the radiator in my Cummins about a year or so ago,and I think the clutch only has about 40K miles on it from when it was replaced by the previous owner while having the NV4500 installed so I should be ok as far as that stuff goes. I know I will need to replace those other seals you mention as well as other things. What about wiring,and such. I know I can use the complete dash,and wiring from my diesel,but what about the added length of the crew cab,and the needed wiring for tail lights and such,is that a easy hurdle to get over?As far as the fuel tank goes I thought I read somwhere not to use the gasser tank because it is galvanized,and diesel fuel eats the galvanization?Is this true?



Thanks again,I am sure I will have tons more questions.



Chris

 

[bgilbert]

Thanks Bill for the reply. You are saying that because the dually has the spindles that stickout further for the dually wheels that I would need to swap them over to a normal 3/4 ton spindle?I was thinking about the swap over to my axle mainly because I don't need/want a dually while having ths 40' long truck. I really only need the capacity of a half ton most of the time,but I love my Cummins,and I already have it stting in my yard. Would it look wierd or drive funny with the dually spindles up front,and my 3/4 ton Dana 70 in the rear?

Yes I would think it would look different. Plus you'd have dually wheels up front and single wheel type wheels in the rear. Wouldn't be able to rotate them. A crew long bed is 21' 6". The wheels would not track correctly. The rear wheels would not follow the same path as the front. Not sure how this would work.

What about wiring,and such. I know I can use the complete dash,and wiring from my diesel,but what about the added length of the crew cab,and the needed wiring for tail lights and such,is that a easy hurdle to get over?

You won't mess with wiring to the rear. You're gonna leave the gasser crews rear wiring alone. It will already have tail, turn and brake lights etc. The only wiring you may consider swapping is the engine and dash harnesses. It will all come off one truck and into the other.

As far as the fuel tank goes I thought I read somwhere not to use the gasser tank because it is galvanized,and diesel fuel eats the galvanization?Is this true?

Not true, it's plastic. But since you are swapping beds, and have everything needed, I would swap out the fuel tanks. You'll need to lengthen your fuel lines. You may try bolting up your diesel metal fuel lines on the crew, then just adding the correct length of rubber line to meet up with whichever end you short, be it the tank end or the lift pump end.



BTW, finding a decent crew that doesn't look terrible and isn't rusted away might be tough. Bill