Cummins Powered M1008 Future Crew Dually

[Sawzall]

I have a 86 M1008 that I installed a 1995 Cummins from a Freightliner chassis and a NV4500 into a few years ago. It has a hybrid super 40/HX35 turbo, marine injectors, Duramax intercooler, etc.





http://s244.photobucket.com/albums/gg25/Sawzall/Cummins%20M1008/

It has been reliable and a fun truck to drive but I need more cab space at times and I like the stability of towing with a dually. I bought a 88 2wd Air Force crew cab that came from Greenland and removed the cab and a few other items.



I bought a 4wd crew dually chassis and D70HD and after removing the cab and box the salvage yard employee destroyed the frame with his loader. I should have winched it on the trailer myself because the loader was huge and they mostly buy scrap and are not used to finesse.

Now the plan is to splice the front section of the M1008 frame to the 2wd crew frame and swap the rear spring brackets. I will also plate the splice and box the center section of the frame. I plan on 19.5 wheels, 245/70 tires, black paint, not much chrome, and aftermarket air.

This might take a couple of years to complete so I am not going to tear down the M1008 until I have everything needed and the body painted.

[exilous]

Is that a 6BT Cummins? What kind of horses are you crankin on that bad boy I bet its a lot of fun. I'd like to get a 6BT Cummins with a NV5600 setup myself but you got a nice rig. Keep us posted on the updates.

[Sawzall]

It is a 6BT. The oil pan and exhaust manifold is different from the Dodge engine. I installed a Dodge clutch fan, harmonic balancer, clutch setup, starter, etc.

I have never had it on a dyno but I have slipped the stock replacement clutch in 5th gear. I would have to upgrade the clutch if I ran it too hard.

Thanks.

[exilous]

Ya, looks good so you at least know you got lots of power. Either way welcome to the forum from CT

[VileZambonie]

Nice project

[Sawzall]

Thanks.

[zieg85]

Very nice project, Welcome from NW Indiana

[choptop]

Sweet, thats what i want to do to this

[Captkaos]

Sweet project!

[Mr Diesel]

How hard was it making the engine and transmission adapt?
I have thought about this conversion myself but not sure if I want all the work.

[BigHemi353]

I agree with Mr Diesel! I want info because I want a 6bt/nv4500/205 combo in my truck when its all said and done. Great Project and I am very jealous! 

Andy

[Sawzall]

I guess it depends on how much fabrication experience you have. I didn't think it was extremely difficult, mostly time consuming.  There are different ways to do the conversion. A 2wd truck would be easier.

The 1st x-member must be modified to clear the balancer. The 2nd x-member was removed and a new one fabricated. I used a Duramax radiator and intercooler, hockey puck body lift to clear the intercooler. The intercooler is flipped upside down and the top nipple was cut off and repositioned to clear the radiator tank. 4" fabricated exhaust with a Walker muffler. Dodge NV4500 with Chevy output shaft and tail housing. The original NP208 transfer case from the 400 turbo bolted right up to the NV4500 with the Chevy tail housing. A better option would be the stock Dodge NV4500 and a NP205 that was behind a 1st gen Cummins with a Getrag 5speed. I used 1st gen Dodge engine mounts, fan and shroud. I used the stock Chevy frame mounts in the stock location, I slotted the lower holes on the frame mount about 1/4" and tightened those bolts after the engine was in to lower the engine as much as possible. I added slots on the frame mounts for the studs of the Dodge rubber mounts. I trimmed the Dodge U brackets and redrilled the mounting holes to move the mount closer to the engine. I did some grinding on the cast iron engine bracket below the lower bolt that runs parallel with the block for additional clearance. With this setup I have about 1/4" clearance between the engine and firewall. I had to dimple the trans tunnel slightly around the bellhousing to engine bolt heads. The rear drive shaft was shortened and the front lengthened 3.5".

Photo link:
http://s244.photobucket.com/albums/gg25/Sawzall/Cummins%20M1008/

[zachs-83]

I was wondering if the bench seat in your truck was from a dpdge. I need to replace the seat in mine and was wondering, if it is from a dodge, how hard it was to get it in there?

[Sawzall]

The seat is from a 96 Chevy standard cab. The bottom section of the mounting brackets must be cut off to get the height correct and mounts that will bolt to the floor fabricated and welded to the seat mounts.

[ccz145a]

Nice work!