Obs dually d-max/allison swap

[john o]

well ive already started an figured id share on this site as well.
the truck- 96 gmc k3500cclb 4x4 dually former 6.5td

the donor- same but an 02 d-max 190k new injectors 20k ago
sic.5 out

my new parts collection

 

[john o]

everything out an ready for some test fitting

i ported my intake horn while the motor was on the stand

my motor mount base plate idea. i traced the stock mounts an cut them outta 3/8" mild steel plate an i was goin to weld my old 6.5 clam shell mounts to the bases an beef them up. cut an drilled checkin for fitment

after they were on i bolted the clamshells to the frame mounts an proceeded with test fit #1

everything looked really good after a little bit of wiggling an twistin so i tacked them on an pulled out

 

[john o]

put some nice tacks on them an bolted the tranny on to see if my idea still worked

everything looked good except for my oil pan still needed to be clearenced so when i pulled back out i did that. its nice havin your own tig welder

i smoothed out the outside so it looked more like factory. im very confident in my welds so i didnt put anything on the inside other than paint

 

[john o]

my finished mounts

after they were bolted in i slapped the t-case in,wired the engine/tranny/tcase up an ran my harness inside the cab.
out with the old

 

[john o]

engine wiring done

an now on to the mess inside

i decided to hook everything up an check for power an the mileage
everything good so far

got the new steering column redone an put in so i can start on the rest of the wiring an fire it up

the d-max skinny pedal plug fit right in to the the 6.5 throttle pedal an it works normal(control on full range of motion)

 

[john o]

so then it was on to the moment of truth. to see if it ran. after about an hour of priming an crankin i could only get it to fire an shut right off. well come to find out the steering column wasnt fully grounded i left 2 nuts off it incase i had to pull it. after i tightened them up it fired up in like 2 seconds. im waitin on my cac to get here so i jus pieced charge tubes together to fire it up. everything sounded really good to me an nothing leaks or knocks after lettin it run for 20 mins
http://s1095.photobucket.com/albums/i471/DIRTYMAXlb7/?action=view&current=053-1.mp4


i got the dash put back in an im workin on gettin my windows an radio an stuff to work now. will update again tonight

 

[btfarm]

You've been mighty busy...:thumbsup:

 

[red]

impressive!

 

[THEFERMANATOR]

First thing is I would say your gonna probably need a body lift to make the hood close unless your planning on a cowl hood. I used 3/16" plate and still had to grind some slots in the center to add clearance on the mounts to get the engine low enough to close the hood. And it still rubs. Judging from your steering linkage clearance, your sitting almost an inch higher in the front than mine is too. And secondly, you did remember to repin the throttle pedal plug as the 6.5 and DURAMAX are wired differently. It may work, but it will cause a ghost limp mode I believe. And you'll get used to using only half the throttle range as the 6.5 pedal uses twice as much voltage range as a DMAX pedal, so roughly 55% throttla application is 100% to the DMAX ECM.

 

[john o]

yea cowl hood is in the plans an the throttle works jus like it did hooked up to the 6.5 1/2 pedal is halfway on the tach an to the floor is rev limiter an on the initial press of it it goes down not quite a half inch b4 it starts raisin the R's

 

[625fireman]

Very nice project.

 

[john o]

more pics tomorrow. got everything but the interior wiring,grill,an wheels/tires done

 

[sudzy]

how hard was the wiring?