Dmax into 93 Crew

[More Power]

With the cutout it lines up, moves forward off the crossmember and rotates downward away from the floor pan so there's lots of clearance. Maybe the crew cab has a different shape to the floor pan.

In my opinion, the newest NVG-261 & 263 transfer cases fit the GMT-400 (90s body style) floor pans as well as the NP-241 (which came stock in the 90s trucks) does.

When the Duramax, Allison and the transfer cases were designed, all GM Powertrain had to work with for package design was the GMT-400 trucks. GM produced at least a dozen test mules using the GMT-400 in the late 90s. It's no coincidence that items like the radiator (bolts right in), firewall shape & clearance for the rear mounted turbo and exhaust system, and even transfer case all match the GMT-400. The divot in the Duramax driver's side exhaust manifold is a perfect fit for the GMT-400 steering shaft. That divot isn't necessary in the GMT-800 trucks.

The Allison and the transfer case are installed in the truck as separate pieces. When doing this, I can't imagine there being a clearance problem, even without a body lift. Even more room with.

I've read where Eric Merchant gmdieseltech.com has a fix for the transfer case issue.

Jim

[Arlie]

I guess there's two possible answers to the transfer case issue. One would be a fumble on my part in the attempt to wiggle it over the torsion bar crossmemeber into place. Or perhaps there are undiscovered factors at work. Either way it wasn't a big deal to make a cutout. I do plan to repair it in a way that leaves some space for future R&R.

At the moment I've got everything back out. My initial goal was to get my motor mount holes drilled with the engine and tranny in place to be sure the angles were right. Perhaps I was obsessing somewhat but since I modified your mount design to raise the engine an inch I wanted to be dead certain about the bolt hole placement.

I'm very pleased with the decision to raise it. With the tranny resting on the crossmember (using the 05 mount) the engine angle is within a couple degrees of the 6.5 setup. With it up an inch and a 2 inch body lift, (end result engine 1 inch lower relative to body compared to your design) I'm hoping the fan will center in the shroud. As noted I have no oilpan interference with the right engine support brace. I will need a replacement hood with more clearance.

I decided to remove the front rad support assembly to make things easier when I put it all back together (should have done this from the start). I should be able to put the engine and tranny in as a unit. Getting the tranny to mate with the engine working under the truck was a bear. When it's all back together I'll take some measurements in the transfer case and torsion bar area so you can compare if you're interested.

I'm now working on wiring. It was a little unnerving to rip out all the cab and under hood wiring. It will be "interesting" installing 05 wiring in a 93 truck and 98 dash/HVAC. I'm waiting for delivery of the dash/HVAC unit with a plan to have the HVAC in before re-installing the powetrain. Things get pretty tight under the hood once the Dmax is in.

As for a windsheild washer container, if I can't find one to fit under the driver battery, I think I'll make one to fit.

Arlie

[More Power]

I'm now working on wiring. It was a little unnerving to rip out all the cab and under hood wiring.

Getting over that psychological hurdle was what held up my project for about a year. Once I committed to it, the rest fell into place.

Save the old wiring & harnesses till after you're driving the truck and everything is working the way you want. You may need bits-n-pieces from the old harnesses to complete the project. The original small harness that fastens to your existing HVAC will remain on the HVAC unit. This harness connects to the fan motor, AC relays, and door motors.

The 2500/3500 frames and front suspension are a little wider in the engine bay (the wheel track is a little wider as well), when compared to the 1500 series trucks. This could account for your not having interference between the oil pan and the front axle mount.

Sounds like progress!

Jim

[Arlie]

Makes sense about the oil pan. I have about a 1/2 inch of clearance so there would have been minor interference with it down an inch.

I saved all my wiring, with labels on the connections. I'm keeping all the old stuff until I've got the new system in place. I guess there will be some uncharted territory since I think you used the original HVAC. I presume you mounted the old controller into your 05 dash?

I have the factory fuel pump that I'm thinking of using to help with delivery through one of Greg's filters. I'll need to figure out the relays etc that make it work. Since I don't get the 200k injector warranty I'd like to protect them.

I noticed you have nice power seats. Are they original? I'd like to upgrade my bench front seat.

Arlie

[Arlie]

Getting over that psychological hurdle was what held up my project for about a year. Once I committed to it, the rest fell into place.

I was thinking about that. If you had not blazed the trail I would not be a participant in this conversion craziness. At the moment I don't know if I should be thanking you.

(just kidding)

Today I took all the HVAC out. Lots of fun trying to figure out where they hid the fasteners... I had taken the air intake grill in front of the windshield off thinking I might find some there... nope but I sure got to clean out a load of pine needles so it wasn't wasted effort.
Hmm... Aha, behind the rad overflow tank!
Inexperience makes for such head scratching I think I'm getting a bald spot.

Arlie

[Arlie]

I'm contemplating relocating the passenger side battery outside the engine bay so I can use the firewall area formerly occupied by the rad overflow for the windshield washer tank.

The current overflow tank has to be replaced by a pressurized version (looking for one of these). It seems this will mount best on the fenderwell like on a factory Dmax behind the airbox. This leaves the firewall area for a battery or the windshield washer tank which is rudely displaced by the Dmax fuse box (kinda necessary).

Any good ideas for relocating a battery?

Or maybe it's easiest to fab a washer tank that will fit under the driver battery and a battery tray for the passenger firewall. Decisions decisions.

I did get a near complete 95 cab from DmaxMaverick (he brought it up from California!) and have gutted it for the dash, HVAC etc. My cab floor is sandblasted, welded up and painted. Now for the scary electrical grafting.

Arlie

[More Power]

I spent a lot of time contemplating where to fit all of the underhood components. It gets crowded pretty fast... In the end, I found that following GM's lead in component location was best, meaning I arranged everything just like GM did in the 2001-2006 trucks. Not only does this produce the best fit, but it also looks best.

You must use a pressurized coolant overflow tank, and its elevation must be pretty close to what it is in the newer trucks - meaning its height relative to the engine. This allows you to fill the system initially and to allow it to properly remove air from the cooling system in an ongoing basis.

The bucket seats and center console I used were out of a 1995 LT Suburban. Once I got the truck running and driveable, I wished I'd kept the bench, but had it recovered in gray leather. The buckets are cool, but only two can ride.

You're only a couple hundred miles away... Lil Red's in the garage if you need inspiration.

Jim

[Arlie]

Make's sense. I think I'll mod a battery tray and fab a washer bottle.
I think I'll look for power split bench seats.

I've got to come up with a name for my truck so when he meets Lil Red there can be a proper introduction.
He's white and big.... Hmmm.
Ideas anyone?

Arlie

[Arlie]

The 95 doors have the handle in a different location. The inner support panels are modified for this and don't fit where they support the relocated handles. Here's how I solved the problem.
(pic upload didn't work, I'll try again)
Arlie

[Arlie]

Hello pictures? I think I need help.

[More Power]

Try this link: http://www.thedieselpage.com/features/photopost.htm

By the way, I used the factory 2001 passenger side battery tray, but fabbed brackets to allow bolting it to the firewall and steel inner fender.

Jim

[93_Burrito]

Arlie,

The later 6.5L TD trucks actually came with a windshield washer fluid reservoir tucked underneath the driver's side battery. GM Part #22143999

The small pump that feeds the fluid to your wipers should swap over from your reservoir to the newer one.


Andy

[93_Burrito]

I want to add some info... the part number I listed above will only net you the reservoir. The filler neck, pump... that's extra. GM Part #22143997 should provide everything.

Also, if you are going to run an intercooler and install it the same way More Power did with Lil Red, this won't work. Bringing the boost tube into engine compartment would put it right in the path of the reservoir. Just something else to chew on...


Andy

[Arlie]

Thanks a bunch Andy. Valuable input. I do plan to do a similar intercooler install but with a Duramax unit. Likely it will come through the same area. I think it will require a fabricated washer tank.

Jim, my home computer internet is down so I haven't been able to try the pics again. I've got them into the album area before but I was hoping to get them into the post.

Coming up... trip to Spalding for coolant tank and battery tray, maybe some kind of compact washer tank.

Arlie

[Arlie]

Here's the pics of the door mod. The first one is the unaltered 93 door. There's text description in the photo album for anyone interested.



Arlie

[DmaxMaverick]

Nice fab job, Arlie! I had no doubt you would figure it out.

[Arlie]

I thought you might recognize that gold paint! The passenger door will go on complete like we talked about.
The hardest part was trying to post the pictures (not really).
Arlie

[Arlie]

Anyone know if the ABS system changed from 93 to 95. I have alldata for 95 and 2005 but not for 93 since there's little I need from there. I have the 93 unit repair manual but it doesn't cover ABS.
I spose $15 extra for 93 alldata isn't a big deal but thought someone might know.
Arlie

[DmaxMaverick]

I'm not sure about the '93. Is it rear wheel ABS, or 4 wheel? I have a '95 ABS module (4 wheel) if you need it.

It might be better to use a 2005 module. I'm sure the 2005 PCM will be looking for one. Another option would be to abandon the ABS altogether. I wouldn't recommend it (I like ABS), but it is an option. We got along for 100 years without them. Disable the I/P lamp and be done.

[Arlie]

I'm fairly sure the 93 and 95 modules will not speak the language of the 05 PCM. I think the older units function independent of a PCM interface, if so I'll hook it up that way. If not I may look for an 05 unit but then it would be a matter of determining if it would mate to a 93 valve and sensors.

I think I can figure out from the 95 alldata manual whether they function independently. If so I'll disable the warning lights and just do a periodic "road test".
Arlie