73-87chevytrucks.com

73-87 Chevy _ GMC Trucks => Diesel Engine Discussion => Engine/Drivetrain => Cummins Swaps => Topic started by: Irish_Alley on January 18, 2015, 10:20:27 PM

Title: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 18, 2015, 10:20:27 PM: The long wait is about over. i pulled my 84 k30 cummins into the shop tonight and started to pull her. the only thing left is the trans bolts. wanted to wait till i had a helping hand before i tried to pull it but let the fun commence. plan is to get it pulled tomorrow then ill pull the 350 out of my crew cab
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150118_173620013_zps34bufph3.jpg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/IMG_20150118_173620013_zps34bufph3.jpg.html)

it is tightly fitted into the engine bay i noticed tonight just how tight. i dont think ill be able to pull it like you would a normal engine. the exhaust manifold is about 1/4" from the firewall and the bottom of the fire wall has been cut out. might have to remove the engine mounts jut to get it out

(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/2014-02-2505-02-42-474_zps1878fc9b.jpg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/2014-02-2505-02-42-474_zps1878fc9b.jpg.html)
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/2014-02-2505-02-38-230_zpsc67c3cf4.jpg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/2014-02-2505-02-38-230_zpsc67c3cf4.jpg.html)
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/2014-02-2505-02-19-071_zpsa341b4bc.jpg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/2014-02-2505-02-19-071_zpsa341b4bc.jpg.html)
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 18, 2015, 10:31:14 PM: The crew
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/20140918_175611_zpskssbk7vj.jpeg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/20140918_175611_zpskssbk7vj.jpeg.html)
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/20140918_175650_zpsdulwixjk.jpeg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/20140918_175650_zpsdulwixjk.jpeg.html)
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/20140918_175640_zpszkbu4zlr.jpeg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/20140918_175640_zpszkbu4zlr.jpeg.html)
Title: Re: 91 V3500 Crew cab cummins
Post by: fitz on January 19, 2015, 07:35:07 AM: This will be a great build to follow.
I'm looking forward to the updates.
Title: Re: 91 V3500 Crew cab cummins
Post by: Captkaos on January 19, 2015, 09:58:09 AM: So you are swapping the motors from one to the other or?
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 19, 2015, 12:05:14 PM: im at least pulling the 350 out of my 91 and putting it in my 94 swb that has a 4.3 or i will just put it in the 350 84. if i put the 350 in my 94 that brings me to my next issue not sure what im going to do with the 84. i know i just got it but dont want to get rid of it, my buddy that i weld with wants it he has a 5.3 to drop in it and wants me to give it to him. but its worth $1500 i cant just give him that type of money lol.

but i have 5 trucks right now and once this swap is done my crew will be everything so i dont really need 3 lwb 4x4. but the 84 is my birth year and besides my crew cab its my only dana 60. my other lwb are my 86 thats sitting on a k20 axle (my first square and first truck i really had) my 79 k20 (mud truck thats needs a new front axle)
Title: Re: 91 V3500 Crew cab cummins
Post by: pholliday1 on January 19, 2015, 12:44:25 PM: To many trucks not enough time...........welcome to the 73-87 website LOL. It's great how you keep us posted on all your projects very interesting keep up the great work!!
Title: Re: 91 V3500 Crew cab cummins
Post by: Dr_Snooz on January 19, 2015, 10:19:16 PM: That's a veeeery tight fit. How'd you get that in there?
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 20, 2015, 12:08:40 AM: i didnt put the cummins in the 84 thats how i got it (http://forum.73-87chevytrucks.com/smforum/index.php?topic=27908.msg232495#msg232495).
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150119_183829804_zps4axdp7hi.jpg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/IMG_20150119_183829804_zps4axdp7hi.jpg.html)

one part that is "rigged up" is the flex plate
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150119_184006673_zps5ydggtp0.jpg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/IMG_20150119_184006673_zps5ydggtp0.jpg.html)
they had to make the bolt holes on the flex plate close to the inside so they welded in washers. this is something that i want to better lol

Part of the fire wall had to be cut out
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150119_185032414_zpssiiwqv1w.jpg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/IMG_20150119_185032414_zpssiiwqv1w.jpg.html)

Dont know if this throttle cable is oem but its total length is about 39"
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150119_192538056_zpsgll5vykt.jpg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/IMG_20150119_192538056_zpsgll5vykt.jpg.html)
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 20, 2015, 11:52:40 AM: so i got myself a little pre-tax check gift
(http://i.ebayimg.com/00/s/MTAwMFgxMDAw/z/90UAAOSwk5FUviGH/$_57.JPG)
(http://i.ebayimg.com/00/s/NTAwWDUwMA==/z/d54AAOSwm8VUviGU/$_35.JPG)
(http://i.ebayimg.com/00/s/NTAwWDUwMA==/z/dUsAAOSwm8VUviF7/$_35.JPG)
(http://i.ebayimg.com/00/s/NTAwWDUwMA==/z/thUAAOSwmrlUviF3/$_35.JPG)
now if i only had a pillar pod. but something i noticed i dont have the screw holes in my pillars. i really dont want to mount anything in the dash cause it doesnt look that clean
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 20, 2015, 11:54:12 AM: once i get my 94 back from the in-laws i think im going to pull the front clip off the crew just to have more room.
Title: Re: 91 V3500 Crew cab cummins
Post by: Dr_Snooz on January 20, 2015, 09:58:35 PM: Quote from: Irish_Alley on January 20, 2015, 12:08:40 AM
i didnt put the cummins in the 84 thats how i got it (http://forum.73-87chevytrucks.com/smforum/index.php?topic=27908.msg232495#msg232495).

My bad, sorry. Still a tight fit though. I'm surprised there aren't some gouges on the firewall.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 21, 2015, 12:14:48 AM: lol its ok. but they did have to cut the firewall at the bottom where the two top trans bolts go. and the very top of the firewall near the cowl is dented for some off reason.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 21, 2015, 01:35:22 PM: fast shipping got them today :-)
Title: Re: 91 V3500 Crew cab cummins
Post by: Captkaos on January 22, 2015, 07:09:03 PM: what do you mean you don't have screw holes in your pillar?
I should have a number of pillar pods in March.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 22, 2015, 08:37:33 PM: theres no interior or holes for screws lol. thought they all came with at least screw hole. unless they got covered up at some point.
Title: Re: 91 V3500 Crew cab cummins
Post by: Captkaos on January 22, 2015, 08:48:09 PM: If it doesn't have the trim it won't have a hole.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 22, 2015, 08:57:28 PM: ok thought they just drilled them all out from the factory then added whatever later. the screws in the pillar if im thinking right you cant really just drill them out with the windshield in can you?
Title: Re: 91 V3500 Crew cab cummins
Post by: Captkaos on January 22, 2015, 08:59:27 PM: Yep. If it came with no trim or headliner there is no holes in the interior.
I converted several by just drilling the holes.
Title: Re: 91 V3500 Crew cab cummins
Post by: Jason S on January 22, 2015, 09:03:08 PM: If it's not there already, the lower hole for the factory trim is the more difficult one to drill. It'd be much easier if the windshield was out, but it can be done with the windshield installed.
Title: Re: 91 V3500 Crew cab cummins
Post by: jkid on January 27, 2015, 07:01:12 AM: Hey Irish I just started a very similar project. Because you took the motor from a running conversion you should be way head. What are you planning to do with all the extra wires in the 91? What trans are you using?
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 27, 2015, 08:02:24 AM: The wires got pulled from right side (passengers side) of the bulk head connector and the wires from the . This all goes to the trans and engine. I pulled the wire harness from the right side of the 84 also I will try to just swap them and run a TCU for the 4l80e. The ecm on the 91 comes from the passengers side of the firewall behind the glovebox. I will mount my TCU in this location.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 27, 2015, 08:30:46 AM: One thing I'm not sure of but the 4l80e used 6 torque converter bolts while the 700 only used 3. If I look up the 91 it shows 2 different flexplates one for the 700r4 and another for the 4l80e. Does anyone know the difference? I'm hoping thins is why they rigged up the flexplate on the Cummins. I think the th400 which should of been on the back of the Cummins and had to be modified to fit the 700r4
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 27, 2015, 08:38:32 AM: Another thing I'm going to have to figure out is the speed sensor on the 4l80 is electronic so I have to tap into the sensor and split it between the TCU and speedo
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 29, 2015, 11:23:14 PM: well its been a long week with the blizzard and all in delaware
(https://pbs.twimg.com/media/B8W5R0XCYAA8Q8e.jpg:large)
think it was supposed to be a foot but we didnt even get an inch. but after that let down i got sick as a dog and today was the first day i got back to work on the truck only worked on it for a hour or so. first thing i did was try and fix the flex plate rigging from the po. they welded three washers about a ½" toward the inside to accommodate for the 700r4 torque converter. so i had to cut them out and fix that. well instead of trying to patch new pieces in i just used washers also but i put 6 on so when i bolt the flex plate back on it wouldnt flex
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150129_181716863_zpstlzajvu5.jpg)
then i fixed the starter. when i tried to take it off the signal wire for the solenoid it was held in place with a phillips head machine screw. so i just cut the wire cause the screw wasnt coming out so i had to remove the screw and replace it. thats about all i did today at this rate i should be done by summer lol.

my front cross member has been modified for some reason thinking to clear the oil pan but idk maybe tomorrow i can try to drop her in
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on February 04, 2015, 11:14:03 PM: first thing i did today was give the cummins a nice bath. the front crankshaft seal was leaking so it had a nice coating of anti rust stuff.
second part was fix the "killer dowel pin" mine looked ok but didnt want to risk it later, but im too frugal to spend that money on something i could rig up and be done.
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150204_132844669_zpspderupmt.jpg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/IMG_20150204_132844669_zpspderupmt.jpg.html)
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150204_132850944_zpsno02x3np.jpg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/IMG_20150204_132850944_zpsno02x3np.jpg.html)
went to the hardware store and got a bolt about a ½" longer than the stock bolt. took a piece of stainless and drilled a hole in it and made it into a teardrop kind of ends up like this
(http://www.cumminsdieselspecs.com/img/pgs/KDP-2.jpg)
i dont know why my timing cover is different than the one pictured above but this is what mine looks like
(http://i23.photobucket.com/albums/b382/board_ryder03/kdp.jpg)
i used a nut that i ground down as a spacer for the bolt and put a tack weld on the tip to help keep the pin in place
mine did turn out a little funny but i dont care no one will see it except on here lol
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150204_132946045_zpskhuksql9.jpg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/IMG_20150204_132946045_zpskhuksql9.jpg.html)
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on February 04, 2015, 11:17:34 PM: then the fun stated i was by myslef but i wanted to put the engine in
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150204_143534672_zpskwvw8bjv.jpg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/IMG_20150204_143534672_zpskwvw8bjv.jpg.html)
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150204_144107691_zpsoqet9w35.jpg) (http://s333.photobucket.com/user/rebel_cowboy_83/media/Chummins/IMG_20150204_144107691_zpsoqet9w35.jpg.html)
at this point i realize the engine prob wont bolt to the trans and i have to start measuring to see if they moved the trans in the 84 back or what.
i was getting tired and i had a button buck that i picked up on the way back from the hardware store in the back on my 94. mind you the weather is now 50° out. luckily my wife is no rookie at dressing a deer and she started it while i took a quick nap
Title: Re: 91 V3500 Crew cab cummins
Post by: LTZ C20 on February 05, 2015, 02:01:00 AM: Nice. I wish my girlfriend would get into that. She thinks animals are cute and fuzzy like bamby, rocky and bowinkle. She don't even like it when I blast the stupid gophers destroying my lawn with 12 gauge buck shot.

I get even tho, pick the mince meat gopher up with a shovel and chase her round the yard with it. Hilarious every time lol.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on February 05, 2015, 04:49:23 AM: sad part is i ~~think~~ know shes done more deer than me. not to long ago she was trapping and skinning everything herself. keeps me on my toes and i know not to screw up lol.
Title: Re: 91 V3500 Crew cab cummins
Post by: LTZ C20 on February 05, 2015, 09:50:45 AM: Haha I got her a 3 inch pink and camo pocket knife for Christmas 2 years ago. Ever since then, she said she keeps it in her purse so if needed she can stick people. She calls it her shank LOL.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on March 18, 2015, 11:52:47 PM: well after a long wait i finally had some time and weather was above 40°. i tried to fit the motor in without moving the trans back and i could fit it but the fan pulley was about an inch from the rad. so that ideal was out. so im going to have to push the trans back took the rear driveshaft out and start to mod the front cross member so the oil pan clears
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150318_175336514_zpsrvscxqdl.jpg)
im going to hopefully get the motor bolted in today. but on a side note since i have to push the trans back it makes the rear driveshaft too long and the front will now be too short. so im going to lift the truck about 4" so it makes up hopefully for the rear driveshaft. havnt figured out what to do with the front but i might have one laying around. for some reason i have a fetish about driveshafts and if i see one i got to have it lol

the width i cut out was about 14". the oil pan fits BUT next time i'll do 15-16" just to give it a little more clearance
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on March 18, 2015, 11:54:11 PM: yesterday we had a fun day and had to tow home a old ford that ran out of gas after hitting the mud pit lol
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Mobile%20Uploads/Truck%20stuff/1426646370038_zpsbw4ehx6i.gif)
Title: Re: 91 V3500 Crew cab cummins
Post by: Captkaos on March 19, 2015, 12:00:51 AM: So you were wanting to leave the trans in the stock position, that is what you were trying?

Chris Lucas
73-87chevytrucks.com
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on March 19, 2015, 12:05:35 AM: yes that way i didnt have to mess with the gear shifter, transfercase shifter, driveshafts, trans crossmember and carrier bearing. thinking it would be easier and cheaper to leave it alone
Title: Re: 91 V3500 Crew cab cummins
Post by: Captkaos on March 19, 2015, 06:32:56 PM: Bummer.
Title: Re: 91 V3500 Crew cab cummins
Post by: 87max on March 19, 2015, 06:40:36 PM: I made my front crossmember out of 2x4 tubing instead of screwing around trying to make factory work, plus it was already cracked lol.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on March 19, 2015, 10:54:18 PM: what i ended up doing was cutting a section out like i posted the picture of. then i took a couple pieces of flat bar one 4" the other 5" and cut them off at 7" then i welded them on the piece i cut out then back to the original spot for the crossmember. to give the crossmember a 5" drop.

Next on the list was the firewall had to be trimmed because the transmission had to be pushed back and the adapter plate on the motor for the trans is a couple inches thick.
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150319_165717471_HDR_zpsttxhagr3.jpg)
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150319_171835353_zpsp8v3xz8o.jpg)
i had already beat the firewall to make it look more compleat by time i took these pictures

then i primed it and painted it. ill get a picture of that in the morning

Then
i moved the transmission back. one good thing i found out was the 4l80e with the transfer case adapter bolts are about 3" longer than on the 4l80e 4x2. so before i even pushed the trans back i noticed a set of holes that seamed to be about 3" apart from the bolts. and sure enough its 3". so i moved the trans back and the bolt holes lined up for the front bolts. but before i drill the rear bolts out i want to make sure its in the right place. and then i ran out of time today and put away everything, so tomorrow i WILL drop the motor in place and bolt everything down
Title: Re: 91 V3500 Crew cab cummins
Post by: Captkaos on March 20, 2015, 05:49:11 PM: Last 2 pics aren't working...
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on March 21, 2015, 11:02:55 PM: (http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Mobile%20Uploads/2015-03/IMG_20150321_151856710_zpsewzlil6u.jpg)
didnt get that far today. had a friend to help but got the motor kind of in place, it needs to be tweaked a little and the trans might have to go back another inch or so. but hopefully Sunday i can get the motor and trans bolted together. one problem is the size of the 4l80e and 205 its hard to push it back cause the center hump doesn't stay for the whole length of the cab. might have to make a new transmission cross member to help drop it down a little
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on June 09, 2015, 01:03:29 PM: i know its seamed like a year since the last time i did anything to the truck. but last night me and two others stayed up late working on getting the motor and trans bolted up and we FINALLY got it all bolted together and the motor bolted down. Had to move the trans back about 4" so now the transmissions crossmember front bolt holes now line up with the old transmission rear bolt holes on the frame. so now comes the part that will require thinking and not just strength.

Im going to keep the fuel pumps in the tanks and use them like lift pumps. after i get the bugs worked out and get her running i plan on using a tank in the bed so i can run a different fuel and not have it contaminate my fuel in my side tanks so today im going to figure out the wiring for the firewall fuse block connection with the help of some on here.

can i switch the pigtail on the 84 with a single tank with the one from the 91 dual tanks? this is the connection on the passengers side of the fuse block not the one going to the lights on the drivers side
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on June 16, 2015, 03:10:59 AM: ok so tonight i spliced the wire harness from the 84
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150616_020027028_zpsrvw50yiz.jpg)
to the 91
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150616_020009271_zpsq9kyqjjn.jpg)
and this is all what i cut out of the 91
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150616_020004453_zpspukbfrq2.jpg)
. i want to keep the original fuel pumps so i was able to keep the fuel pump relay in the 91s wire harness. just cut out the pcm
this is the 84's firewall connection
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150611_102540200_zpspxblcsbg.jpg)
then the 91s
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150611_102642968_zpsak4pmiol.jpg)
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on June 17, 2015, 09:22:26 AM: got a few more things done last light. got the power steering plumbed up, then i hot wired the fuel pump relay and tried to drain the tanks. only to get about 11 gals out of one tank then the pump quit working. could hardly hear it work while it was pumping then it just stopped. flipped the tank switch (thought i had some gas in that side) and you could hear the pump scream but nothing came out. got most of the wires ran.
just need to remount the fuel pump relay on the drivers side wheel well (cause thats where the cummins oil pressure switch is at).
the motor isnt sitting quite right so i need to fix that
find a front drive shaft and cut down the rear.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on June 19, 2015, 08:17:55 AM: So last night i went to napa to get a oil pressure switch for the 91 crew cab. its the type that sense the oil pressure and if its above 3psi it will kick on the fuel pump. so i want the cummins to have the same effect so the pump is only running when the engine is running. ill rig up a delay relay to prime the system on start ups. but i confused the heck out of the new guy at napa, normally i deal with an older lady whos been there since i was a kid and a couple other ladys. they seam to know somethings but dont question me when i ask for something weird.

But this is how the story goes. i ask for the switch for a 1991 chevy v3500. he replies "what year, make and model" i repeat it i could tell hes never heard of a v3500. but i let it slide didnt feel like a history lesson lol. he says ok i dont have it in stock but i can get it tomorrow. i ask for price he says 15.99. i know i get a discount but its not that good and i know they should be around $30. so i ask to see it on the screen. he shows me the regular one (its not his fault he doesnt know) so i explain appearance of the one i need and just wait...... he couldnt find it. i know they have it cause i looked it up online a little before i went in there just didnt know if it was in stock. so i said this is for the 350 right? he said it didnt give me any option. then he clicks on a box and it ask 5.7, 6.2 or 7.4. so he clicks the 5.7 and it still didnt show it. i then tell him to go to a 87 v30 and search for it there. he ask "are you sure its a 5.7" i just started to laugh and say yes. he finally finds it he said its under a 6.2. i then tell him i need a brass pipe reducer, and he just looks at me like im crazy. so i break the news to him saying theres a cummins in it not a 350. he was blow away and ask "why would you do that. i have a couple fords that will out pull the cummins any day. why wouldnt you just get a ford". i replied "cause then i would be in more work and would still pull the engine and put a cummins in it." we then go to the fittings and once they find it he said "i dont think it will work, cause the fittings hole is smaller. at this point i was getting ticked and just said "ill take it"
Title: Re: 91 V3500 Crew cab cummins
Post by: LTZ C20 on June 19, 2015, 10:00:55 AM: Those priceless moments when you confuse the crap out of people.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on June 26, 2015, 08:52:39 PM: so i ended up ordering the "little black box" for the tcu. the box is about $200 this is only a backup plan if i cant ge the other tcu's to work. but if i go with this black box it pluggs into the main connection on the trans and a power wire and a ground to lock the tcc
(http://www.jakesperformance.com/images/6525dfbd8eff6ab930b0f4703bcbe261.jpg)

Manual Controller
Pink= 12v ignition
Brown= Ground through switch for TCC
Lock up
Yellow= D1 Trans brake (if equipped), ground through switch for
activation.
Black/Red= D3 Trans brake (if equipped), ground through switch for
activation.

now i just dont know how im supposed to get the speed sensor to work with my stock dash. anyone know how to do this?
Title: Re: 91 V3500 Crew cab cummins
Post by: scorpion on June 27, 2015, 09:28:51 AM: Quote from: Irish_Alley on June 19, 2015, 08:17:55 AM
So last night i went to napa to get a oil pressure switch for the 91 crew cab ... but i confused the heck out of the new guy ... when i ask for something weird.

"What year, make and model" .... at this point i was getting ticked ...

That was a funny read and just about sums up my experiences with parts stores in general when "my guy" isn't working. It's frustrating entertainment.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on July 01, 2015, 07:23:29 AM: so i have the truck driving around the shop. still waiting on the black box and need to get a rear driveshaft made. right now shes only front wheel drive and she wont shift out of first. mocking up the pillar pod and have the 3 sensors for the gauges ran (boost, egt and trans temp). the fuel pumps seam to be working good. need to transfer the fuel pressure gauge from the 84 to the 91. only problem is i was trying to keep all the gauges looking stock and the white gauge doesnt look so good with the glow shift black gauges lol.

the pillar pod was fun, i dont know the size of the glow shift but they were too big. we have this nice little tool a "deburring tool"
(https://encrypted-tbn1.gstatic.com/images?q=tbn:ANd9GcQ_LZJXQFOBRsEkXHgY1iDQRWCm-dvvOCLtxwQaOmJPk1GAxuSvcQ)
and i just went around the pod a couple times to shave off what needed to be taken off. the pods still fit snug and they dont turn, painted them black and had to shave off some paint

the hydro boost was fun also. took me a while to figure out why i was having so many bubbles and each time it would overflow the reservoir and flow out. come to find out it looked like there was enough fluid in the reservoir when i would check it but once i started it it would suck it down and it would be sucking air. the sucking of air would then turn into bubbles and once shut down it would over flow. the way i had to fix it was unhooking the return like up on the master cylinder plugging the line that goes back to the pump and running some more hose off they cylinder with a hose clamp into a cup. start the engine and pump the brakes, after each release the cylinder would release power steering fluid into the cup then once i filled the cup i would then pour power steering fluid that was settled down so there was no air in the new fluid back into the reservoir. did this till i saw no more bubbles in the cup and the problem was fixed, topped off the reservoir with fluid and was done.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on July 01, 2015, 07:49:14 AM: crappy vid but it was late.
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/th_VID_20150629_011652206_zpszgjhcldx.mp4) (http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/VID_20150629_011652206_zpszgjhcldx.mp4)
the black smoke is cause there was no exhaust pipe on the turbo. there is now a short section that ends right around the transfercase. so now all thats black and its not a good ideal to sit in the truck while its idling ::)
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on July 01, 2015, 09:09:04 AM: also the dipstick
it would of been a good ideal to order a "flexible" dipstick but for $80 i decided to make my own.
first design didnt work too well
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Mobile%20Uploads/2015-06/IMG_20150623_191734603_zpskxwxteuf.jpg)
it was supposed to allow it to bend under the firewall and it did but it was at a bad angle and ended up sitting near the turbo
second design i have no picture of but i measured the old dipstick and cut some 5/8 hose to fit. i then cut the bottom part of the dipstick nipple off leaving about 2" above the lip that sits on the trans. after that i cut about 3" off the top of the dipstick so the original dipstick would be held in place by the metal tube. then i made a bracket and bolted it to the firewall. ill try to get a picture when i get home
Title: tripple pillar pod
Post by: Irish_Alley on July 06, 2015, 07:52:37 PM: not really much room for the dipstick to take a picture
(http://forum.73-87chevytrucks.com/smforum/index.php?action=dlattach;topic=30149.0;attach=34022;image)

The pods i sanded down with some fine grit paper to get rid of the seams and painted them black
i put everything in place and found out where i wanted to set the pods at marked it out then came the hard part (drilling holes in the good trim)
(http://forum.73-87chevytrucks.com/smforum/index.php?action=dlattach;topic=30149.0;attach=34024;image)
at first it was the two retainer holes then i drilled holes for the wires. im not going to say what size holes i drilled cause yours might be bigger depending on the retainers.

like i said i had to trim mine up to make them fit the gauges and it was still a tight fit so i didnt want to fully seat the gauges till i knew everything was in a good place
(http://forum.73-87chevytrucks.com/smforum/index.php?action=dlattach;topic=30149.0;attach=34030;image)
after i had it mounted i didnt like the way the two retainers where holding it down so added a 3 more one to each corner except the inside one at the bottom due to not being able to get a drill in place with the gauges mounted

Crappy photo will get one better but heres the test run
(http://forum.73-87chevytrucks.com/smforum/index.php?action=dlattach;topic=30149.0;attach=34032;image)
i like how clean the retainers look but the con is once they are in you cant take them out so easy. i ended up cutting a hand full off due to a problem i had
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on July 10, 2015, 03:30:20 PM: had a pressure problem with the transmission, after shut down it would spew fluid from the dipstick area. come to find out we pinched the vent line on the transmission between the transmission cross member and trans mount. felt so good i hooked up againts a early 90s f250 with a 7.3. im against hooking up to other trucks but this boy wouldnt keep his mouth shut. since im against hooking up and believe it will only break parts we stuck to the dirt roads around the farm and made a gentlemens agreement that if one was to win he wouldnt drag the other around, i told him if he did this once he stops i would come out of my truck swinging. and it proved another point of mine its all about traction i was only front wheel drive he was only rear and we just dug holes lol. would loved to pulled him but i dont like the ideal of going on the road. but next weekend is truck pulls and i should be there
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on July 10, 2015, 03:57:08 PM: this seams fitting
(http://media.giphy.com/media/pIwSSY4FUvs0E/giphy.gif)
https://youtu.be/YQwYNca4iog
Title: Re: 91 V3500 Crew cab cummins
Post by: Captkaos on August 14, 2015, 12:03:16 AM: Did you not screw them down with the Screws? The 3rd one included is for the top spot...
Feedback? Can you send me a pic to share?
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on August 14, 2015, 12:10:32 AM: Didn't see any screws. Might have missed it in the box lol. And just reread your installation write up and see you had the same ideal for more screws
Title: Re: 91 V3500 Crew cab cummins
Post by: Captkaos on August 14, 2015, 12:31:42 AM: Hmmm. you got one of the first ones. It would have been loose in the bag... Sorry about that...
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on August 14, 2015, 07:02:53 AM: lol even if it was in a bag i felt like a kid at Christmas when i opened it so i probably would of never even seen that either
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on August 15, 2015, 11:45:35 AM: well i was having a squeal at certain times and it only happened at speeds above 18 mph and wouldnt stop till i completely stopped. replaced the carrier bearing because i figured it was probably the original and been exposed to salt and everything else. i also had a vibration only on acceleration. i just knew it had to be the bearing cause tires shouldnt do that. well maybe i was wrong when i put in my drive shaft and thought i phased the 2 piece shaft when i installed it cause it wasnt phased at all was 90° off. so i removed the front half of the shaft along with the bearing and beat on it for a while then i just took the cut off wheel to the bearing and cut it off. put the new one on and PHASED the drive shafts and the squeal is gone along with the vibration.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on August 15, 2015, 12:17:09 PM: so next problem is, right after i got the truck inspected (with the 350 tbi) you could smell gas really bad around the left side fuel tank. figured it was a loose filler neck and couldnt really see any drips. well last night after sitting for a couple days i started it up and noticed the fuel gauge wouldnt go above 9 or so psi, switched tanks and it jumps to 12. didnt pay it no mind figured it was a weak pump on that side so i went up to the shop (only 50 ft away) and parked it on the concrete to clean up the bay before i pulled in leaving the truck to idle. after cleaning the bay up i noticed a puddle under the left side tank but thought it must have been some water from the storm we had a couple days ago draining out of the bed. pulled into the bay and it kept dripping, nothing fast but a nice puddle quickly formed.

rolled under the truck and i could smell diesel and sure enough i dipped my fingers in the fluid and it was diesel. so apparently the inspection guy tugged a little hard on those fuel lines and caused them to crack. im not blaming him cause if they did that they were in bad shape anyway. still have to drop the tank to see whats cracked but its next on the list
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on August 18, 2015, 09:32:03 PM: So took a little trip to the dump today. Filled up when I left with a dump trailer when I Hit the scales I weighed in at 12840 lbs. Trans temp was about 190-200 norm is 180 did pretty good hauling it and once I made it back home I topped off again got 16 mpgs
Title: Re: 91 V3500 Crew cab cummins
Post by: LTZ C20 on August 19, 2015, 01:50:29 AM: Not to shabby.
Title: Re: 91 V3500 Crew cab cummins
Post by: fitz on August 19, 2015, 10:57:55 AM: Glad to hear that its up and running.
What's left to do before its cleared for daily driver status?
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on August 19, 2015, 11:55:08 AM: oh its a daily driver now lol. still doing little things, want to get the trans automatic again but i can deal with driving it manually. i was driving my 94 that gets about the same mpg and has ac but i much rather roll with the windows down and the knock of the diesel. i do have to put exhaust on it, it stops about a foot before the transfer case
Title: Re: 91 V3500 Crew cab cummins
Post by: LTZ C20 on August 19, 2015, 01:31:37 PM: That's gotta be loud.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on August 19, 2015, 02:42:53 PM: loud? yes. drowns out wife on a 4 hr trip??? lol it has its benefits
Title: Re: 91 V3500 Crew cab cummins
Post by: LTZ C20 on August 19, 2015, 09:10:39 PM: Lol
Title: Re: 91 V3500 Crew cab cummins
Post by: fitz on August 24, 2015, 08:28:02 PM: Money well spent.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on August 26, 2015, 12:51:28 PM: so found out this morning that i incorrectly hooked up my tcc switch. i used a toggle switch with a led, and the wire coming from the "black box" has 12v and you need to ground it to lock up the tcc. so i figured i could wire it up as a ground wire to the led and the power wire only. this would turn on the led but not draw enough to tell the "black box" to lock the tcc. not really knowing how it would feel with the tcc locked and the cummins i just "thought" it was working.
last night i was thinking that maybe i did hook it up wrong and as it turns out i did but now it works so this is just a fyi
Title: Re: 91 V3500 Crew cab cummins
Post by: LTZ C20 on August 26, 2015, 02:13:06 PM: Haha, I remember when I pulled the 2 prong brake switch out and swapped in a 4 prong switch for my TCC to work. I used a continuity meter, mapped out the way the switch works, then wired it up the way it should work. Put it all together and it didn't work and the brake lights were on when the pedal was released. So I swapped the 2 plugs and it worked perfectly.

Sometimes even tho we know it should work 1 way, it just doesn't amd it does the way we think it shouldn't. Murphy's law sounds like it to me. Haha.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on August 26, 2015, 04:41:12 PM: got the new tiresthe old tire size was 235/75/16
(http://forum.73-87chevytrucks.com/smforum/index.php?action=dlattach;topic=31386.0;attach=29674;image)
the new size is 285/75/16
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150826_172208040_HDR_zpsgvbncwke.jpg)
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150826_172214838_HDR_zpsc0coxp0h.jpg)
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20150826_172223934_zps8q26awol.jpg)
Title: Re: 91 V3500 Crew cab cummins
Post by: LTZ C20 on August 26, 2015, 07:50:16 PM: You got new wheels or new tires? The wheels all look the same, the tires look to be the same also.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on August 26, 2015, 08:36:43 PM: Lol new rubbers/tires. Those 3 pictures are the after. I'll edit it to show the before
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on October 21, 2015, 11:26:30 AM: went to the dump yesterday with half a tank of fuel and my tool box and after dumping the trash i weighed in at 7440
Title: Re: 91 V3500 Crew cab cummins
Post by: ehjorten on October 26, 2015, 01:43:55 PM: I hauled some stuff for my father-in-law yesterday to the dump. 1/2 tank of gas in one tank only and I weighed-in, on their scales at: 3.23 ton or 6,460 lb!
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on October 26, 2015, 03:35:48 PM: The Cummins dry weight is 940 5 Gallons of oil lol I can't have too much in my tool box I don't know where the difference is, maybe bad scales?

These are 2wd but they claim Thiers with a 454 is at 6900
http://www.dieselplace.com/forum/76-speciality-forums/127-3500-dually-trucks/294344-curb-weight-80s-gm-c-c-dually.html#/forumsite/20625/topics/294344?page=1
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on October 26, 2015, 03:52:37 PM: The Cummins dry weight is 940 5 Gallons of oil lol I can't have too much in my tool box I don't know where the difference is, maybe bad scales?

These are 2wd but they claim Thiers with a 454 is at 6900
http://www.dieselplace.com/forum/76-speciality-forums/127-3500-dually-trucks/294344-curb-weight-80s-gm-c-c-dually.html#/forumsite/20625/topics/294344?page=1

According to the 87 manual the
For gas motor
(http://forum.73-87chevytrucks.com/smforum/index.php?action=dlattach;topic=30149.0;attach=30776;image)

Diesel
(http://forum.73-87chevytrucks.com/smforum/index.php?action=dlattach;topic=30149.0;attach=30780;image)

People with suburbans claim 7.5 or so with the cummins
Title: Re: 91 V3500 Crew cab cummins
Post by: Jason S on October 26, 2015, 04:26:51 PM: I'm thinking that Tommy Lift is adding on a bit of extra weight...
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on October 26, 2015, 04:57:40 PM: Lol I guess I see it so much I never put any thought to it
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on October 26, 2015, 05:04:39 PM: Another guy in his crew cab cummins is around 7600 his 2wd dually burb Cummins is at 7400
Title: Re: 91 V3500 Crew cab cummins
Post by: ehjorten on October 28, 2015, 01:23:39 PM: I am coming in at about 1,000 lb. over curb weight. I only weigh 200 lb and I carry minimal stuff in the truck...maybe, just maybe 100 extra lb. So that is still an unaccounted for 700 lb. I am running 35" Toyo Open Country Tires which are a little heavy over other tires, so that probably accounts for some, and I am sure the dump scales are not that accurate or precise.
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on January 21, 2016, 03:27:07 PM: so its finally got cold enough i had to add a second battery.
so i got a new battery that was the same amps as the other.
this being a gas motor i had the charcoal canister so i had to make room for the battery to sit in place, so it had to go.
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20160121_011938795_zpsytpo7grd.jpg)

the bracket from the canister would now double as the bracket for my battery
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20160121_023748093_zpsxmjegbxa.jpg)

now i never had something i built fail so i may have over done with strength, but it held up. so i added a couple braces, they aint the strongest thing but anything else i thought would be overkill
(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20160121_025650545_zpsnc7xklf4.jpg)

(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20160121_025655398_zpsrv8ry3jh.jpg)

i also added another bolt to hold it more to the fender

(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20160121_042014719_zpsdxudmoqz.jpg)

and a bungee cord to hold it down lol if you look you can see the washers i welded to it also. the bungee is temp till i make another hold down

(http://i333.photobucket.com/albums/m387/rebel_cowboy_83/Chummins/IMG_20160121_044641605_zps4gd1paqc.jpg)
Title: Re: 91 V3500 Crew cab cummins
Post by: 2011laramie on May 01, 2017, 08:50:18 PM: Irish, I cant see the majority of the photos. anyway you can get them working again??
Title: Re: 91 V3500 Crew cab cummins
Post by: Irish_Alley on May 02, 2017, 01:56:43 AM: think so. i took them off photobucket cause of data usage on there meant to transfer them to here but never got around to it.