I can see now why there are so few 5.9 Cummins conversions in a Chevy 4x4.

Analogy. Same as fitting a size 12 foot in a size 10 shoe.

Almost have the 5.9L set. The Bragg auto crafts shop did not have a tilt-able engine sling, and this caused havoc. A must on the job. My work-around was a chain hoist and second cherry picker and two chains. And patience.

First; to even get this engine to go in the engine cavity-without removing the entire front front radiator body support, you have to remove the harmonic balancer and speed sensor off the 5.9. Did that - move on.

With 4WD trucks: getting the 5.9L oil pan to slip in past the front diff requires loosen the diff and push it forward max. The oil pan will not slip past the diff without this. I had already pushed the transmission/transfer back 2". (Final set will have the tranny/transfer back 2" and drill new crossmember holes.) You have to remove the rear drive shaft in initial install. Once marrying to tranny input spline, you re-install drive shaft to lock the input.

I'm in, past the diff now, have the tranny input in clutch spline. Lacking only rotating engine to allow tranny align pins to seat. Sounds much easier than done. Everything fits and, but mass and gravity of the 5.9L in the size 10 shoe cavity takes any notion of "man-handle" out of the install equation. I stopped last night, because to rotate the engine, will require a bottle jack and bellhousing to tranny bolts just about 5mm longer for set. Of course the crafts shop did not have a bottle jack. Must rotate engine weighted to hoist chain which in effect pushes against chain. The adapter is aluminum, and OEM bolts might stripp. Err on caution and just buy longer bolts for the install.

So here I am, 1/2" to tranny seat, a mere rotation and few bolts away. Only the align studs prevent total seat. Spent 4 hours in that position last night. Should finish set tonight.

This job is like wrestling (no fake though). It looks easier when watching and theorizing than when doing. Don't try this at home without proper training and facilities. Somebody could get hurt.

Seriously. Wow. What a job!

When I have the 5.9L in motor mounts, and truck back in movable condition, I am trailering it home to plumb and fit and wire. I could go broke paying these bay fees.


Wayne
Owner of a 93 one-ton chevy 4x4-5 speed - with a yet-ran 300HP 5.9L Cummins diesel. That will change.

[ 04-22-2004, 05:56 AM: Message edited by: DogDiesel ]