The Stovebolt Site Forums The Parking Lot Big Bolts Diesel Engine for my '59 3800

I scored a 2004 6.6l Duramax Diesel engine for my truck today. I got it for $ 3000.00. It is supposed to have only 20,000 miles on it. It looks pretty clean, so I may believe that number.

Pics can be seen at http://community.webshots.com/album/562816192hotBxO

Lane

Man great find I also like how clean your garage is wish mine looked like that.

Lane,

That would be a great project to document (photos, write up, etc) for the Tech Tips projects -- it would go nicely with the one Grigg will be writing up on his Detroit Diesel upgrade.


John

I am?... Sounds like a good idea, I just never thought of that, I better start taking notes if there will be an exam at the end.

Lane,
Sounds like a great project, do take bunches of pictures.
The details of your swap won't be much like mine, but you still may find something useful in the pictures of my conversion, linked below. I am a few days away from a running chassis.

Grigg

Also,
You will certainly have the power, do you have plans for good brakes and reliable steering? (edit) I see you have newer axles with disc brakes up front! What are they from?

To make the best of the swap you will also need to change your rear axle gears so you can efficiently drive the speed you want.
rule of thumb is engine peak torque rpm, or just faster, is the rpm you want to be at when in high gear on the highway at your preferred speed. I like this calculator http://www.onlineconversion.com/bigger_tires.htm
What transmission will you run? did you get the Allison, and is it the 5 or 6 speed? the 5 speed can be reprogrammed to be a 6 (extra overdrive) no parts needed.

Grigg

John / Grigg;

Yes, with a nickname like 'Photo', I will take lots of pictures! And I'll do my best to do a write-up for a tech tip (maybe it'll turn out to be a "Don't try this at home!").

I'm a lot more than 'a few days' away from a running chassis, more like a few years!

The axles I'm using are a Dana 60 (front) from a 1987 K-3500 one-ton truck (was a tow truck) and a Dana 70 (rear) from a 1993 Chev P-3500 cube van. They both have 4.11 gears in them. They are also both dually axles!

Yesterday I picked up a NP 205 transfer case ('76 chev one ton), a hydroboost and master cylinder ('81 chev one-ton) and a power steering unit ('82 chev) for my beast. I was looking for a transfer case from an International pickup as they were remote, mid mounted or divorce mounted (your choice of terminology) separate from the transmission, but was unable to find one. I'm going to try to convert mine to this style. I'm currently looking for the divorce-mount input shaft (to take a yoke) and will have a plate machined to hold a seal in place. Shouldn't be too hard (Yeah, right!).

The Duramax came complete with power steering pump, alternator, air-conditioning compressor, etc. already mounted. The only thing I can see that's missing is the top plastic shroud that says '6.6l Duramax'.

I haven't got a transmission yet, but have been pricing both 5 and 6 speed Allison tranny's. My concern is transmission size - I would like to leave the master cylinder and booster beneath the floor, but I'm not sure if I'll have room along side the Allison.

As far as tires, I'm hoping to find a tall, skinny set of 'Ground Grips' that will be similar to what was available in the late 50's or early 60's. If I have to cruise at 55 or 60, so be it.

I had to laugh when the guy I bought the Duramax from asked me "are you taking it up to 1000 horsepower?". i replied that I had no plans for that yet, but would love to have the ability to do it in the future!

Lane

I don't have a really good picture up, but take a look at these
http://rides.webshots.com/photo/2058331900080251109TjwEMM
http://rides.webshots.com/photo/2761442110080251109HsfdcV
I managed to fit the hydrobooster and master beside my Roadranger, and I believe an Allison 1000 or 3000 (same case size) is smaller.
If I were to do it again I would mount the booster and master on a stand alone bracket about a foot back and run a long tubular push rod (about 7/8" diameter?) back to operate it from the stock brake pedal.

Consider changing axle gears to make it suit your driving habits and get good fuel economy, fuel is expensive down here, but even more so up where you are..

Grigg

I would tend to push you towards a 6spd if you have the choice. In my 2007 GMC 4500 I have the 6.6 with the Alison 5 spd, and as much as I like it, I know guys with the 6 (and have driven their trucks) and if I had it to do again.... I wont buy another 5...
~Gator

that will be a real cool conversion, i wish i had the duramax in my 2003 2500hd, they are a heck of an engine.

my friend's dad has an 2006 3500 4x4 duramax with allison, and that thing is unreal, we had a 35 foot enclosed gooseneck loaded down with atvs/fuel/camping stuff, and you just let in on the throttle and you can pass big rigs like they are standing still or may be 75

I think you should have plenty of room for the hydro boost between the Allison and the frame. I am putting an Allison AT540 and a hydro boost in my 56 6100 the frame rails are 34"s apart, as with most big trucks and I am using a bracket that mounts the hydro booster and master cylinder to the frame using the stock pedal. I don’t know how the AT540 compares in size to the 1000 but I can tell you the 540 would be a tight fit in the trans tunnel of most pick ups and I have plenty of room so I think you will be fine.

Man oh man,, you're doing exactly what I intend to do to my 1950 1.5 ton!! I'll have more work to do trying to fit that honking engine between the fenders though.

I'm also planning on using a Dana 60 front, but I'm retaining the 6.17 gear ratio and adding the same to the Dana front. I've got a Brown Lipe Aux tranny to step it back up for highway cruising,,,, that and an S6-650 6-speed or an NV-4500 5 speed OD should make it highway friendly. I'm still debating whether to use the NP271 transfer case that comes behind the S6-650, or a divorced NP205, and put it behind the brownie. That way I could have the brownie in OD while it's in 4x4. That would make for a pretty long front driveshaft, but it would keep the u-joint angles down and permit me to eliminate the driveshaft carrier and go to a single piece rear driveshaft.

I haven't looked into it in much detail, but I'm thinking I'll use a more modern steering box, and possible move it outboard of the frame, using u-joints to shift the steering column over as it exits the firewall.

Anyway, it sounds like a GREAT project! Hopefully we can trade some stories and help eachother out. I know a lot of people say the duramax swap has too much electronics work involved and some even say it's impossible... Naysayers,, it's just more work. If you haven't looked into the electronics work involved, there's a guy on eBay that has done such a swap into a 70's Chevy and has a CD of all the information it took him to wire everything up correctly and retain stock or Autometer gages. Here's the link:

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=200209212849&ssPageName=MERC_VIC_ReBay_Pr4_PcY_BID_IT&refitem=200198331089&itemcount=4&refwidgetloc=closed_view_item&usedrule1=CategoryProximity&refwidgettype=cross_promot_widget&_trksid=p284.m183&_trkparms=its%3DS%252BI

Grigg,

Does this look like it would work? : http://good-times.webshots.com/photo/2372048480098190200RWTQaW

I added some more pics to the album today.

I mounted the power steering box today and placed the booster and master cylinder for the brakes in place. This should leave room enough for the transmission.

I'm now (slightly) leaning towards a 4L80E or 4L85E transmission. The diesel guy and my local Chev dealership has been actively looking for a stand-alone controller for an Allison tranny and cannot find on that works. If he can't find one, I'll probably have even more difficulty. I know that the controllers for the 4L85E are available and I can get this transmission beefed up to handle 1200 HP. (www.gearstar.net). It would also mount up to my transfer case a lot easier.

Any thoughts?

Lane

It looks close, double check that your PS lines will connect and you can get a wrench on them with it installed so close to the frame.
It does look like you will have plenty of room for the transmission.

I have had mine mounted in two different trucks about like you have yours mocked up. If I do it again I would try to mount it farther back to make it less cluttered beside the transmission, but then again I was not worried with a transfer case possibly being in the way?

Grigg