1981 CrewCab remodel - Dodge Cummins Diesel Forum
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post #1 of 104 (permalink) Old 03-24-2014, 03:09 AM Thread Starter
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1981 CrewCab remodel

So after buying a few CrewCabs last year, I finally acquired this one:



1981 first year of the Power Ram, W250 w factory Dana60, NV435 4spd, 318cid, 23spline205... And hideous red racing stripes... I think they are what caused the truck to want to go out of service. Oh yeah it's only got 46,000 original miles. All of which were acquired under 55mph.


'89 W250 SC Dana61/70-2UA rear Disc conv. 727
'81 CrewCab Remodel https://www.cumminsforum.com/forum/89...b-remodel.html
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post #2 of 104 (permalink) Old 03-24-2014, 03:13 AM Thread Starter
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View from the back


Btw, I can't do this all in one post cuz sometimes my iPad deletes every thing when I'm switch back and fourth from photobucket

'89 W250 SC Dana61/70-2UA rear Disc conv. 727
'81 CrewCab Remodel https://www.cumminsforum.com/forum/89...b-remodel.html
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post #3 of 104 (permalink) Old 03-24-2014, 03:30 AM Thread Starter
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whatevs, I switched to a PC. okay...

so I tore out the engine/trans/xfer case sometime in November or January, I cant really remember. I also removed the seats and work mat and then let it sit another month till sometime late Febuary







fortunately, tthe entire truck are really solid and for the most part even surface rust free. the pans had some lifting of paint but that was it. I just wire wheeled the already bare metal spots after removing the lifted pant, and treated with phosphoric acid.

'89 W250 SC Dana61/70-2UA rear Disc conv. 727
'81 CrewCab Remodel https://www.cumminsforum.com/forum/89...b-remodel.html
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post #4 of 104 (permalink) Old 03-24-2014, 03:49 AM Thread Starter
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before I preceded any further, I finished removing the front clip, the dash and all that lies beneath it. and spent several hours vacuuming, washing, degreasing hitting several areas with strong solvent, and wire wheeling things like glued on jute and melted backings to voltage regulators

I wanted to start with the interior and firewall. This would include: cleaning up the firewall; welding some holes closed; cutting an even rectange out of where the bulk head harness passes thru the firewall and flipflopping it to move the HOLE over ~3" to the driver side to make room for the Clutch Master Cylinder to mount; drille hole for clutch master cylinder; needed to lay sound deadener on the inside of the firewall too(last crewcab, i did it to the enginebayside of the firewall too); mount factory sound deadener mat; mount HVAC blower box; and install Getrag pedal set... and bed line the rest of the inner tub or passenger compartment of the crewcab.












'89 W250 SC Dana61/70-2UA rear Disc conv. 727
'81 CrewCab Remodel https://www.cumminsforum.com/forum/89...b-remodel.html
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post #5 of 104 (permalink) Old 03-24-2014, 04:10 AM Thread Starter
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I really wanted a nicer looking firewall than what I did on the '75 Power Wagon and I'm going back with white on this '81. I didnt Shave anything byanymeans and most of it gets covered up anyway

before, which is the same as the above


afta


I love White... idk why its my favorite color for automobiles... something super classy about it-like old school 1920-40's kinda classy or maybe its cuz its so hot where i live.

theres only one direction to go after this and it's to start adding everything that mounts to the firewall... inside and out.



with most big items mounted(brake booster, blower box, steering column, pedals, clutch slave MC, ect) it was time to address the front frame horns before i could place the motor/trans combo

'89 W250 SC Dana61/70-2UA rear Disc conv. 727
'81 CrewCab Remodel https://www.cumminsforum.com/forum/89...b-remodel.html

Last edited by jbtsurf; 03-24-2014 at 05:15 AM.
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post #6 of 104 (permalink) Old 03-24-2014, 04:31 AM Thread Starter
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at this point i may have not taken too many pics as i got excited and carried away with the work. I also had intentions of addressing the suspension. Although I didnt want as much lift as my last truck, I also didnt want as much lift as even 4" either. I have two sets of 4" lift springs but chose just to add a little integrity back to the originals. I was wanting 2" of lift; at the very most 3. Turned out my cousin had some front add-a-leafs. I figured i could make them work and not get over 3in. so out went the old 2nd leaf in the leaf pac, and in went a new on with extra arch.


pull the old leafs first, of course


the new leaf had a buckle riveted to it. they came in handy after all was said and done.
the old leaf had the buckle on the third leaf so thats where i reinstalled the new buckle.



i added the 6* shim cuz i would also be running a longer shackle which rotates the axle more than if you were to lift from both spring mounting points.


one more...

and the finished product.


normally, i would replace all the bushings with poly; but upon inspection, the frame upper shackle bushings were like new shiney rubber and i could live with the spring eye bushings. so i saved myself the trouble

'89 W250 SC Dana61/70-2UA rear Disc conv. 727
'81 CrewCab Remodel https://www.cumminsforum.com/forum/89...b-remodel.html

Last edited by jbtsurf; 03-24-2014 at 05:16 AM.
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post #7 of 104 (permalink) Old 03-24-2014, 04:48 AM Thread Starter
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just about caught up. Wednesday, I got the front part of the frame painted and the suspension mounted. Thursday was mounting the axle after cleaning and painting... all seals, bearings, hubs and kingpins checked out. Friday, placed the motor and trans. still have to do KDP and valve cover gaskets to the motor... maybe a few other things. Spent Saturday night manipulating metal so that i could mount the transmission/xfer case with new Poly Mounts. Ive never seen a single 4x4 1st gen Cummins that didnt have Squirshy BOOB rubber mounts... i do believe these overly squishy rubber mounts to be a contributing factor in Rear Main Seal failure and probably other problems too. I regularly keep several sets of these poly mounts in stock...its the one thing ive had to replace on every 4x4

you can see the long shackle... im still a little worried about the cross tie hitting the frame. there is more clearance than the original spring eye with the factory shackle but not enough for my comfort... would prefer no cross tie over this. wish it was offset some, oh well. the lift came out to about 2.5" with the motor weight. Maybe more cuz my measured reference point was with the original motor out.


you can see the getrag poking through


this is what the poly mounts look like but the pic is from another truck

'89 W250 SC Dana61/70-2UA rear Disc conv. 727
'81 CrewCab Remodel https://www.cumminsforum.com/forum/89...b-remodel.html

Last edited by jbtsurf; 03-24-2014 at 04:54 AM.
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post #8 of 104 (permalink) Old 03-24-2014, 04:59 AM Thread Starter
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this is a common issue ive run into with the trans mount on these conversions... they end up being 3/4" to 1-3/8" off and slightly wider. so close but not quite


the bolts are centered in the holes but dont line up with their correlating hole.


better angle for depth perception

'89 W250 SC Dana61/70-2UA rear Disc conv. 727
'81 CrewCab Remodel https://www.cumminsforum.com/forum/89...b-remodel.html

Last edited by jbtsurf; 03-24-2014 at 05:19 AM.
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post #9 of 104 (permalink) Old 03-24-2014, 05:06 AM Thread Starter
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other than that, yesterday, i turned it around in the driveway and plucked the bed, rear wiring harness, dropped the rear axle and fuel tank. planning on getting started back tomorrow, Monday. hopefully, fire up the motor the middle of this week and start paint prep.

'89 W250 SC Dana61/70-2UA rear Disc conv. 727
'81 CrewCab Remodel https://www.cumminsforum.com/forum/89...b-remodel.html
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post #10 of 104 (permalink) Old 03-24-2014, 07:58 AM
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Great find, and condition. Subscribed

*1969 Kaiser M715 5/4 ton Military Truck - Non-IC 12V - Stock, NV4500, NP202
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post #11 of 104 (permalink) Old 03-24-2014, 10:37 AM
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Dang you got right to it, very nice!

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post #12 of 104 (permalink) Old 03-24-2014, 11:01 AM
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93/81 Dodge crewcab longbed, nv5600,
92 D-250 a-518
97 dodge ext cab long bed nv 4500
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