IIRC, '94 was the year the 6.5 went electronic. It is not uncommon to swap a 4911(mechanical IP for 6.5TD) onto a later engine to lose the electronic weak point. Getting the PMD off the pump and onto a better heat sink seems to be the most common fix as it is a simple task, especially compared to swapping to mechanical IP.
the reason i ask is because i have a 1976 3/4 ton chevy i was gonna do a cummins swap on. The 6.2 or the 6.5 would be a drop in and go. with some research i found that the 6.2L had alot of problems. I bought a 1996 rollover with a 6.5 td. Id rather have a mechanical pump than to swap all the wiring. And im still thinkin about the cummins. Thanks for the info.
I put an early '94 mechanical pump on my '96. Engine runs quieter, smoother, starts easier. The big problem is making the tranny shift - you gotta have a 3rd party controller. Not a problem, but the price goes up about 700 bucks.
Did this conversion myself, twice. Once on my '93 C3500. That was easy because of the 5-spd manual tranny. Only tricky part is to adjust timing, I needed to twist the pump and lines pretty far to driver's side to get enough advance.
The other was my wife's '94 K2500 Burban. That was a challenge because of the 4L80 auto. I tried to build a conversion box that used the signal from the DB2-mounted TPS sensor to emulate the DS4's throttle pedal, but that didn't work well. I didn't want to buy an aftermarket stand-alone tranny controller because, in the first place, the main point in replacing the DS4 pump by a DB2 was to keep Bill Gates out of the truck!!!! Then, these things are very expensive, and having to buy Windows just to be able to program the module was OUT of the question, period.
So, after a few weeks of research, I DID find a good solution. I designed & built an analog transmission controller for the 4L80. It fits into a 6'' x 6'' x 3'' plastic box.
It is a bit complex for someone who isn't into electronics, but for anyone used to IC's and solder, it is no big deal to put together and uses parts that are easy to find. Strictly analog, no digital.
Cost of parts: a rough guess is $100.
I haven't patented or ever published the circuit design, although it works beautifully and allows adjustment of shift points. The circuit reads vehicle speed through the tranny's output speed sensor, reads throttle level through the pump-mounted TPS sensor, and controls shifts, torque converter locking and line pressure. For fun and ease of trouble-shooting, I put five LED's that show status of speed sensor, shifts, torque lock and line pressure regulator.
Transmission operation is smooth but responsive once properly adjusted.
My controller works just as well in the bitter cold as on the hot summer days, and has been doing its job flawlessly for the past two years. It probably has 12,000 to 15,000 miles on it now.
There might be a market for my controller??? don't know. The way I see it, throughout the years I have had my ass saved a hundred times by vital info displayed on the web by nice people who like to help others... so if anyone is interested, I might write down my notes into a clear schematic and put it out here for people to have fun with.