81 crewcab cummins swap project

[moparman89]

Originally Posted by johny5

sweet , im just finishing mine up right now.

Got any pics or a link to yours...would love to see it!

[Lugnutz]

Yea, they are pretty cool. I was bitten by the crewcab bug too, and ended up with 3 of them. A shorty 4x4 and two 2x4 long beds, all from the Air Force base.

I have yet to see a 4x4 long bed in the 81 to 93 body style though. A lot of fun to drive. I used the 4x4 to go camping and pull the boat. Had a few guys come over to me and talk to me about the good ole days in the Air Force.

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1992 W350 CTD 5spd, Stans 4" exhaust, BHAF - Crewcab donor
1985 W350 4x4 Crewcab Dually, So far - Dana 80, NV5600 6Spd, and just arrived 96 215hp p-pump engine

[johny5]

Originally Posted by moparman89

Got any pics or a link to yours...would love to see it!

85 crew cab conversion

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currently building 85 crew cab with 93 cummins 5 sp

[moparman89]

Well I know its been a week now so heres the update ...OK...so I spent most of the past weekend working on getting the motor out...never thought it would had been such a pain in the @!@ to pull the motor out with the 4spd attached...I will never do that trick again...maybe it was just me I don't know but things just wouldn't clear....oh well I did get it out of there after spending most of Sunday working on that...took off some other stuff from the firewall on Saturday.....pulled the transfercase out today...so now what... ...well still plenty work to do...ok so I have some decisions to make now..am I gonna paint this thing or not....if so I would have to finish gutting the cab and deciede what color I want it....well I still have some other things to do next ..pull the bed off..pull the tank out..and what ever else I see..

Some thing I would like to know...I will find out sooner or later....I have a 205 transfercase in this truck and thats whats in the 92 cummins truck..well thats what the sticker under the hood says....are they both the same or are the splines different? I counted my splines on the tailshaft I counted 23.

[moparman89]

Boy what a fun weekend...but its not over yet..
I'm havin so much fun...the last time I had this much fun was when I restored a '69 Charger I had...just hope this project doens't take as long as that one did..
Well heres what I got done Sat. and Sun. ...removed the rear bumper,removed steering column,removed gas tank(of course I had to pump out 11 gal. first),then removed all four doors.....what a day....gonna try to get the windshield and dash and seats monday?

[johny5]

its coming along,
is there some coating on the floor ?
not sure if you figured this out yet but you will need to move the square wiring plug over and inch and a half for the clutch master .
there is also supposed to be a filler piece for the stock clutch linkage in the older auto trucks, i just welded mine up

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currently building 85 crew cab with 93 cummins 5 sp

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Last edited by johny5 : 10-29-2009 at 01:04 AM.

[BIGrusty250]

how are you going about mounting the slave cylinder on the firewall?? i am currently putting a 81 cab on my spare 92 d350 frame and i have noticed the 92 cab is double walled with a square hole, the 81 is a smaller circle hole with a single wall. i was gonna hole saw the square pattern out and weld spacers to it and then weld it in the 81 cab to make the slave cylinder work. how are you going about that??

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92 250 2wd 5spd, 230 pump, 100 horse injectors currently, 16 inch electrical fan (bye bye power robbing factory fan), hx50 and 6 inch stack setting on the bench, time to save save save for a clutch!!!! BIG thanks to Richard at Coaltrain Diesel .

[moparman89]

Originally Posted by johny5

its coming along,
is there some coating on the floor ?
not sure if you figured this out yet but you will need to move the square wiring plug over and inch and a half for the clutch master .
there is also supposed to be a filler piece for the stock clutch linkage in the older auto trucks, i just weled mine up

OH NOOOOOOOO!!!! No I didn't know that...
Great now I have more work to do....I figured the wirirng harness hole was in the same place..I thought I would just have to drill a new hole for the clutch stuff?
As for the floor...it had been coverd with some kind of bed liner stuff,it was like that when I got it.
I talked to a guy once that did an older 70's style cummins swap..he had to swap out the whole firewall...maybe I should just do that?? He claimed it wasn't that bad of a job

[moparman89]

Originally Posted by BIGrusty250

how are you going about mounting the slave cylinder on the firewall?? i am currently putting a 81 cab on my spare 92 d350 frame and i have noticed the 92 cab is double walled with a square hole, the 81 is a smaller circle hole with a single wall. i was gonna hole saw the square pattern out and weld spacers to it and then weld it in the 81 cab to make the slave cylinder work. how are you going about that??

Yeah well....haven't figured that part out yet..
I'm getting ready to start tearing inot the Cummins truck now.

[moparman89]

Well as of today got alot of things done,the window is now out...hmm..oh yeah NOT IN ONE PIECE.......cracked it...looks like have to buy a new one now.....then I got the dash out,the heater box, oh and put the steering column back in so it would make it easier to move around....then decided to pull that truck out of the barn and move it to the other side...that will be put on hold for right now....moved the '92 Cummins truck in,and gonna start gutting it!

OOOPPS.....

[johny5]

Looks like its coming along, I spent the weekend working on mine too.
It was really easy to move the wiring and the clutch slave .
Once the parts truck is striped take a piece of plywood and put it over the holes on the 92
Stick some screws/bolts through the ebrake holes to hold it
Trace them out and hole saw, jig saw square hole .
I used the plywood to hold the hole saw while drilling

I used a right angle drill to to mount the slave mount.
Is this bracket what was refereed to as double wall?
Also if you look at the second pic when you see the square hole ,the top right of the hole used to be the old center.

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currently building 85 crew cab with 93 cummins 5 sp

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Last edited by johny5 : 09-08-2009 at 02:01 AM.

[JNDcumminscowboy]

whach ya gunna do with your dually???

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''1991 w250 LE 4x4 5 speed non Ic 3'' off the turbo 6'' tip'' pump turned up! Alot more "COAL ROLLING''