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Discussion Starter #1 (Edited)
We are almost done with a 12V Cummins into a K2500 Suburban 4x4.

The Suburban is a 1996 GMC and was a 454 Vortec truck when we started. We used the original transmission 4L80E with a controller. We ended up putting a 1" body lift on to make life easier although it wasn't required.

This entire swap was done without discharging the Air Conditioning.

Most all of the swap parts were from Autoworldmt.com - they were great during this entire swap. They supplied the motor mounts, trans controller, A/C mount, alternator mount, transmission adapter and tachometer drive.

Transmission was move back 3" to accommodate the longer Cummins engine. We moved the transmission coolers to underneath the truck, we used the factory cooler and a cooler from Derale with a fan on it.


Here is the engine, it is from a 1993 Dodge:



Another engine shot:



This shows what we had to cut from the core support to use a 1994-1998 Dodge Truck Intercooler, we did end up cutting more than what is shown but not much:




Here the engine is sitting on the mounts in the truck:



Another in truck shot:



Here is a clearance picture with the stock IFS and the Cummins Oil Pan. It doesn't touch but it's close. We have to countersink a few of the bolts:



Originally we tried to use the stock dodge manifold but ran into clearance issues since this Suburban has dual heat and A/C:






We ended up using a 2003 Dodge Manifold which is a lower mount and cleared everything:



 

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Discussion Starter #2
More Pics

Here is a shot of the engine with everything wired (but the wires aren't loomed back up yet), most of the intercooler piping and the radiator hoses are done:



Here is is with the wiring more complete and this was after we drove it:




Here it is with the intercooler, radiator and condenser installed:



Close up shot of the driver side intercooler:




Here is the truck after today:

 

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Looking real good. Thanks for posting the pics. Hows the trans controller working? Is the hood going to hit the A/C compressor? How long did it take to get the parts from Autoworld, I might be using there mounts for my 93 chevy dually.
 

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Discussion Starter #5
Looking real good. Thanks for posting the pics. Hows the trans controller working? Is the hood going to hit the A/C compressor? How long did it take to get the parts from Autoworld, I might be using there mounts for my 93 chevy dually.
Autoworld was very quick with getting stuff to me. They had most everything in stock and the item they didn't have in stock (I can't remember what it was now) only took a week for them to fabricate up.

The hood did hit the compressor and I could have made the stock hood work I think but instead I just put a cowl hood on it and still had to trim for the A/C nipple and the dryer next to it.
 

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Discussion Starter #6
did you have to do anythig to make the a/c kick on with the pcm or did it work

It is unhooked right now but it worked fine when I had it hooked up.

On the computer, we pulled 35 pins out that aren't needed anymore and about 200 ft of wire, luckily, everything works -- except there is a check engine light -- haha.
 

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Thanks for the pics, they answer a lot of questions I had. Any idea's on what you are going to do with the parking lights......looks like the intercooler is in the way?
 

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Discussion Starter #8
Thanks for the pics, they answer a lot of questions I had. Any idea's on what you are going to do with the parking lights......looks like the intercooler is in the way?
The parking light has 2 bulbs, both do the same thing, I was going to eliminate the backside of one side and seal it up with some sheet metal or something... Or if I can find some LED parking lights, I will swap them out for those as they would be much thinner.
 

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Discussion Starter #10
i tried navigating the autoworld site with no luck, what do the charge for the a/c bracket?
Not sure for your application, you would have to email or call them, they are very good to deal with but their website definitely needs updating.
 

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Discussion Starter #12 (Edited)
Super nice and answered alot of questions. Thanks for the pics. I have a 98 3500 srw that I want to this to. Great Job!
Thanks! I did forget to mention a few things:

The intercooler we got was new aftermarket and was wider at the top (near the headlights) than a stock one. We have to have it cut and plated to clear the headlights, I have seen a stock one work with just removing the Dodge brackets but this aftermarket one was different. Here is a pic of the cooler we received:




Here is a pic where you can see it with the brackets cut off and the top plated. It cost about $175 to do have this plated at a hot rod shop and they also pressure checked it after it was done:

 

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what year intercooler is that .....or at least what year stock dodge equivelent
 

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ok i guess it just looked big for some reason
 

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How much have you driven it? Which tranny controller did yo go with? I've been looking into the OptiShift Transmission Control System. Also were you able to put a mech fan or electric?
 

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Discussion Starter #17
How much have you driven it? Which tranny controller did yo go with? I've been looking into the OptiShift Transmission Control System. Also were you able to put a mech fan or electric?
I've only driven it 100 miles or so, still working bugs out like the power steering return lines weren't totally tight so they leaked a tad, little things like that.

The controller I went with was the Simple Shift:

http://www.powertraincontrolsolutions.com/simpleshift.php

I like how it is easy to adjust and seems to work very well. The only issue I have is it shifts out of first rather quickly but I am a little apprehensive to 'wood it' off of the line. I am not sure what the instant torque might do to stuff. I know the 454 had more torque but it came on more gradually and at a higher RPM.
 

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Discussion Starter #18
How much have you driven it? Which tranny controller did yo go with? I've been looking into the OptiShift Transmission Control System. Also were you able to put a mech fan or electric?
Fan, could have gone either way but since I needed a different fan drive, clutch, fan, etc. Once I priced everything out I was only $50 off of the electric flex-a-lite so I went with that.
 

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man, that is one sweet build. Just what I want to do to my 97 burb. I've found a 95 donor motor/tranny/tcase and ALL related components that have 84K miles. Still scrounging odds and ends, and trying to decide which axles to go with. If you don't mind I would like to ask alot of questions once I get more into my project.
My son and I are about to finish up on his.....a 93 S10 with a 1st gen 5.9
 
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