84 crew cab cummins conversion and suto to manual swap

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84 crew cab cummins conversion and suto to manual swap

Postby KTA » Sun Oct 12, 2014 8:10 pm

Things I have learned so far that may be of interest to anyone attempting a job like this. The clutch mount will not clear the bulkhead wiring in stock position. I narrowed it a half inch and re-bent the bracket on the pedal to align up and it all cleared. The wiper motor is in the way all the time when installing the motor, best to get one from a later model and count on using it in the swap as well as it is smaller and tuned different to give more room. The diesel harness uses a different bulkhead connector than the 84 so if you want to use a factory harness you have to have the whole thing, even the connectors for the tail lights and turn signals going to the rear are different. U-joints are different sized so drivehafts have to be swapped and shortened or lengthened as required. The transmission mount needs an inch added to it and the holes elongated an inch so you can get the mount in without redrilling the frame for the crossmember. The right hand side still has to be drilled 3 holes though because the support for the crossmember is different I suppose to allow more clearance for exhaust. the voltage regulator needs to be moved up onto the cowl also as it won't clear the engine in its original location. I did start the engine in the truck today by hotwiring it and it ran! I have to get the rear driveshaft lengthened 5inches and put the front end grille radiator and stuff back together and finish sorting out the wiring and it should be driveable at least.
Fleet of Junk: 1989 D350 627rwhp 1300 tq B-1/Hx60 twins, KTA pump/injectors, ported head, BIG fuel supply. 13.75@ 109.5mph 1/4: 1992 W350 Cab-chasis, 1993 W350 ext cab cust.370 inj Hx40/16cm 290rwhp hydroboost brakes,1984 D350 crew-cab another project.
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby KTA » Wed Oct 15, 2014 7:36 am

So since I had the wiring problem with the diesel and pretty much every connector being diffrent on my 89 I started changing out the dash harness with my 89 Parts truck and at the same time decided I might as well add the AC from it to my Crew cab. Getting the ducts installed without breaking the dash was a bit of a pain but putting the AC box in inplace of the heat only one was about the easiest part of the swap as nothing had to change! The blower motors did have a diffrent wiring connector but since I used the harness that was originaly with it it hooked up fine. Now I guess I have to change the steering column as well since the 92 manual column I have doesn't have the right wiring hookups and neither does the original 84. Does anybody know if there is a good way to delete the shifter off the column on the 89? While I had everything out I went ahead and installed the factory sound proofing from the 89 so maybe that will help make it a bit less noisy.
Fleet of Junk: 1989 D350 627rwhp 1300 tq B-1/Hx60 twins, KTA pump/injectors, ported head, BIG fuel supply. 13.75@ 109.5mph 1/4: 1992 W350 Cab-chasis, 1993 W350 ext cab cust.370 inj Hx40/16cm 290rwhp hydroboost brakes,1984 D350 crew-cab another project.
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby dazedandconfused » Wed Oct 15, 2014 9:18 am

Should be able to knock the pin out and install the manual shifter covers. When I converted my 83 over I just had to swap everything from the 93. Even when I swapped cabs I had to change that wiring and stuff out of that cab and it was a 89-90.
Big Andy
1983 Dodge D150 that has been repowered with a 93 Cummins/518 running gear AKA The Ugly Duck! I would much rather build them then buy them.[
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby CumminsPower59 » Wed Oct 15, 2014 10:29 am

Andy, I know for sure that the inner shifter assembly has to come out or get cut off for manual covers to fit...aren't the older ones an assembly? Like shift cover and what not all one piece that moves when the shifter moves?
Ike

91 W350 SRW, 3.07's, NV4500, 370's, THD LPPP, Super HX40, 2nd gen IC swap, BHAF, Isspro's, 2" lift, 285's on 3rd gen 17"'s.
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby PToombs » Wed Oct 15, 2014 5:45 pm

IIRC I cut the tabs for the shifter off mine. I tried to remove the shifter sleeve from the column and screwed up the plastic pins that are supposed to break and let the inner shaft collapse in an accident. Real PITA to get that fixed.
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby KTA » Wed Oct 15, 2014 7:31 pm

5 1st gens sitting here and everyone has a different column and wiring connectors!!! Damn Dodge and living up to their "Different" slogan!!! My best option is to use the column from the donor that matches the wiring harness. It is funny my 84 harness has bigger wires in it for the gauges and lights and no melted connector. The 89 has a melted headlight connector. I guess since I will have to make an adapter to hook my taillight, turn signal fuel gauge and other rear harness stuff up I need to put my tails and turns on a relay so a trailer doesn't melt it down. My 84 has like 12ga light wire and this 89 must be 16. I guess since they added 100 other wires for a RWAL system that works like crap they decided to take the wire out of the things that needed it.
Fleet of Junk: 1989 D350 627rwhp 1300 tq B-1/Hx60 twins, KTA pump/injectors, ported head, BIG fuel supply. 13.75@ 109.5mph 1/4: 1992 W350 Cab-chasis, 1993 W350 ext cab cust.370 inj Hx40/16cm 290rwhp hydroboost brakes,1984 D350 crew-cab another project.
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby thrashingcows » Wed Oct 15, 2014 10:15 pm

When I bought my 84 Crewcab it had been converted using a 89 motor, all the 89 wiring and column. It was converted to a NV4500 at that time too. So it had the old column shifter as well. I used the old stub on teh column to house my Tach...worked pretty well, and hid the old shifter stub. ;)

Here's a pic...

Image
1984/93 Dodge Crewcab, W350, 1 Ton SRW, long box, 330K Km's, M&H spacer, 366 spring, fuel pin to deep side, 14cm housing, Piston LP, PS IC, Isspro Boost, Pyro and tach, NV4500, 29 spline NP205, 3.54's.


Check out the build....http://www.dieseltruckresource.com/dev/ ... 05923.html
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby KTA » Thu Oct 16, 2014 5:46 am

That is a cool idea on the tach. I have been looking at the truck and fooling around with it some more and I think it looks bad with the 93 grille. I think an 89 grille makes it look taller with the 3 slots as opposed to two. The 93 grille looked nice on the 4wd but seems to make my 2wd crew cab look like a vaccum cleaner. I also think it looks like the 89 grille would allow more air to the radiator and IC as the bottom several inches ends up coverd with the 93 stuff. The headlight buckets are mounted to a backing plate and then mounted to the grille on the 93 core support. Anybody tried modding them or bolting the lights on straight like they used to be to get them low enough for the older grille to work? It is a lot of trouble for cosmetics I guess, but hey what part of this swap hasn't been a lot of trouble? lol
Fleet of Junk: 1989 D350 627rwhp 1300 tq B-1/Hx60 twins, KTA pump/injectors, ported head, BIG fuel supply. 13.75@ 109.5mph 1/4: 1992 W350 Cab-chasis, 1993 W350 ext cab cust.370 inj Hx40/16cm 290rwhp hydroboost brakes,1984 D350 crew-cab another project.
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby dazedandconfused » Thu Oct 16, 2014 7:56 am

My 93 core the headlights sit in their own buckets. I plan on moving them to run my 83 grille when I get around to body work.
Big Andy
1983 Dodge D150 that has been repowered with a 93 Cummins/518 running gear AKA The Ugly Duck! I would much rather build them then buy them.[
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby KTA » Fri Oct 17, 2014 7:44 am

I am certainly glad I didn't bid this job for somebody else!! I sware that every part on one of these trucks must be some hand crafted one off piece. NOTHING swaps or interchanges. I thought I would easily swap the column from my parts truck, but was wrong. I got it out and when I went to put it back in it was an inch short of reaching the lower coupling. I ended up having to take a hammer and beat the end out to get it to telescope and reach.(no spring on this shaft) This version column I have doesn't even show up in my parts book and it isn't made like any in the Service manual. All my other columns are made out of like a wire mesh so they can collapse but this one is two solid pieces of tube with plastic pins holding it, then on the bottom it was loose in the column and there is a ball bearing just above the coupler, but the bearing won't slide up the shaft beacsue the shaft gets bigger as it goes up so the bearing runs in nothing, and even if it would go up it is too small to fit the tube tight to remove the play. I gave up and just rigged it by wrapping electrical tape around the shaft till it filled the tube and wouldn't wobble. I guess at some point I will have to try the salvage yards with the slim hope that I can find a manual column with the right hookups that isn't loose. :-( So frustrated with this project. At least I picked up my lengthened and retubed driveshaft today so maybe I can drive it at least.
Fleet of Junk: 1989 D350 627rwhp 1300 tq B-1/Hx60 twins, KTA pump/injectors, ported head, BIG fuel supply. 13.75@ 109.5mph 1/4: 1992 W350 Cab-chasis, 1993 W350 ext cab cust.370 inj Hx40/16cm 290rwhp hydroboost brakes,1984 D350 crew-cab another project.
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby dazedandconfused » Fri Oct 17, 2014 8:12 am

When I swapped columns I had to swap the piece that goes to the gear box as well. Mine was way off.
Big Andy
1983 Dodge D150 that has been repowered with a 93 Cummins/518 running gear AKA The Ugly Duck! I would much rather build them then buy them.[
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby thrashingcows » Fri Oct 17, 2014 9:02 am

KTA wrote:That is a cool idea on the tach. I have been looking at the truck and fooling around with it some more and I think it looks bad with the 93 grille. I think an 89 grille makes it look taller with the 3 slots as opposed to two. The 93 grille looked nice on the 4wd but seems to make my 2wd crew cab look like a vaccum cleaner. I also think it looks like the 89 grille would allow more air to the radiator and IC as the bottom several inches ends up coverd with the 93 stuff. The headlight buckets are mounted to a backing plate and then mounted to the grille on the 93 core support. Anybody tried modding them or bolting the lights on straight like they used to be to get them low enough for the older grille to work? It is a lot of trouble for cosmetics I guess, but hey what part of this swap hasn't been a lot of trouble? lol


This fellow over on the DTR did just what you suggest.....

http://www.dieseltruckresource.com/dev/ ... 19515.html
1984/93 Dodge Crewcab, W350, 1 Ton SRW, long box, 330K Km's, M&H spacer, 366 spring, fuel pin to deep side, 14cm housing, Piston LP, PS IC, Isspro Boost, Pyro and tach, NV4500, 29 spline NP205, 3.54's.


Check out the build....http://www.dieseltruckresource.com/dev/ ... 05923.html
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby KTA » Mon Oct 20, 2014 7:02 am

Well I was able to drive the truck into work today so I can do some power washing and more finishing work. Apparently the fuel gauge senders in 84 have different resistance than the 92 dash I am using as the fuel gauge shows about 5/8 full with 5gal in a 30gal tank. Possibly I can use a resistor to correct it? My other problem is my speedo isn't working. My wait to start indicator flashes all the time, but I don't have the grids hooked up or the ksb attached since its an 89 controller but the engine is a 92 so the ksb would be ass backwards. Anyways it appears that when the wait to start flashes the speedo reads so my needle bounces from 0 to about the speed I am driving constantly. I assume there is a ground somewhere that is not hooked up maybe causing this issue. There were 6 wires in my crew rear harness and there must be 15 in the 89 I spliced into it. Anybody got any ideas where to look for the problem? My oil pressure temp and voltmeter all seem to at least work ok. My only other issue is my washer pump won't power up but I think the switch must be bad as it doesn't run the wipers either when you push wash, but it works in every other mode.
Fleet of Junk: 1989 D350 627rwhp 1300 tq B-1/Hx60 twins, KTA pump/injectors, ported head, BIG fuel supply. 13.75@ 109.5mph 1/4: 1992 W350 Cab-chasis, 1993 W350 ext cab cust.370 inj Hx40/16cm 290rwhp hydroboost brakes,1984 D350 crew-cab another project.
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby Tacoclaw » Mon Oct 20, 2014 7:45 am

Here's how mine is wired, 92-89 harnesses. The vast majority of those wires are ABS stuff I believe. I can get you more info on specific wire positions if you need but it'll be a while since I'm at work. They're somewhat comprehend-able as those deutz connectors are numbered.

92 harness from cab.
Image

89 harness to frame.
Image

The grounds gave me fits for a while, there's one that bolted to the dash framework between the stereo and steering wheel, right around where the ashtray slides in. Then I finally lost it and cut all the underhood grounds I could find and extended them all to the ground lost of the battery. It's been smooth sailing since then. :grin:
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Re: 84 crew cab cummins conversion and suto to manual swap

Postby KTA » Mon Oct 20, 2014 8:27 am

That is pretty much what the packard connector on the 84 looks like and that is how I have it wired. The 89 harness has 2 connectors for the rear harness. I believe one was a 6pin and the other is a 10 or 12 and it looks like the ones they use on the engine.
Fleet of Junk: 1989 D350 627rwhp 1300 tq B-1/Hx60 twins, KTA pump/injectors, ported head, BIG fuel supply. 13.75@ 109.5mph 1/4: 1992 W350 Cab-chasis, 1993 W350 ext cab cust.370 inj Hx40/16cm 290rwhp hydroboost brakes,1984 D350 crew-cab another project.
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