MoparFins

Members Projects => MEMBERS Project Cars in Progress => Topic started by: Brian on March 27, 2010, 07:40:52 PM

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 27, 2010, 07:40:52 PM
....and RAE stands for, Ruff Around Edges....(http://www.moparnuts.com/forums/images/smilies/happy.gif)

I just drove him home today from Kamloops...about a 3 1/2 hours from my place.  I went up a checked the it out last weekend, liked what I saw and bought it. 

So without further ado....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1416.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1418.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1413.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1410.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1414.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1415.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1420.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1421.jpg)

It's a 84 Dodge Crewcab long box, D350 1ton.  Has a 89 Cummins with a 96 NV4500 and a set of 3:54 gears.  I drove 210miles and didn't even use 1/4 tank of fuel, and that was over the extreme mountain passes too boot!!

Lots of work to get it to where I want it but at least I can drive it, and enjoy it as I go.


thrashingcows2015-01-07 01:20:10
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 27, 2010, 07:51:28 PM
One of the first Cummins pickups.  No intercooler.  84 1/2 had them.
 
Rare one.  4 Door.  I like the interior.  That must have been an SLT.
 
Congrats!  What do you want to know about those beats?
 
Let's see.  Get it up in the air and check the ball joints and front brakes.  Front end bushings.  Those were the biggest issues with those.  Those problems weren't fixed until the 2nd gem series in 99.  Oh yeah. . .front wheel bearings too.  They just weren't quite strong enough for the extra weight.
 
46 RE trans.  Hopefully it's been upgraded to the 48RE guts.  Get a trans cooler on that ASAP.  A BIG ONE!  Allot of trans problems will go away
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 27, 2010, 07:53:24 PM
I'm sorry. . .I just realized it's a 5 speen manual Brian. . .  Those trans missions were pretty stout.  But the clutches. . . .
 
How many miles?
 
POLARACO2010-03-27 23:54:54
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 27, 2010, 08:16:20 PM
Yeah I have to still go through everything on this one.  Make a list and start with the safety stuff first.

What is the lift pump?

It was supposed to have a new clutch assembly, but it was making noise by the time I got home? Also 4th gear makes a bit of racket too.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Stewart Van Petten on March 27, 2010, 09:00:00 PM
Looks like a nice old truck! To bad they did not make more of the 4 door ones. Hopefully it will only take a bit of tlc to make it a safe and reliable truck for you. There are many after market parts available depending on your needs/wants. I love the fuel economy of the mechanical injected engines of that generation. I averaged over 30 mpg with one piloting some wide loads to Alaska and back with the last year of the mechanical engine.

Good luck with your project!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on March 27, 2010, 09:19:50 PM
Nice. And yeah, there should be an air intake that can use some major improvement in design/shape to boost the air flow to make her pull that much harder. Check the oil level on the tranny, and if it vibrates when in gear, that is a slight indicator of a problem, usually with a secondary shaft getting wobbly, those transmissions only die when they are low on oil. The guy you got if from in Kamloops didn't have a nice 72 Challenger by any chance, did he?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Jacques on March 28, 2010, 02:17:41 AM
This is very nice! Never seen one of those!

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Stan Paralikis on March 28, 2010, 03:06:34 AM
I take it that it ain't going to fit in the garage...
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 28, 2010, 05:52:26 AM
[/QUOTE]


 
The lift pump is external.  It lifts the fuel from the tank and pumps it to the injector pump.  If the lift pump is bad, you'll be loosing power.  Most importantly, it robs the pump of the needed lubricants.
 
FASS makes one, http://www.rollinsmokediesel.com/cat-fass-hpfp.cfm (http://www.rollinsmokediesel.com/cat-fass-hpfp.cfm)  or you should think about one of these guys.
http://www.rollinsmokediesel.com/cat_dodge_cummins4.cfm (http://www.rollinsmokediesel.com/cat_dodge_cummins4.cfm)
 
Here's a Canuck Made Intercooler  http://www.rollinsmokediesel.com/pd-1994-2002-dodge-59l-bd-cool-it-intercooler.cfm (http://www.rollinsmokediesel.com/pd-1994-2002-dodge-59l-bd-cool-it-intercooler.cfm)
 
BD is the best out there and the one I use.  The only problem is you'll need all the plumbing to install it.  But you'll be glad you did.  Better MPG's and performance because of lower intake temps, and lower EGT's.  Significant of probably 300 degrees or more on that rig.
 
You should get around 20 MPG highway with that.  The intercooled versions got 22 to 25.  Ahh brings back memories.
 
Rollin Dope Diesel is a good dealer for this stuff.  Allot of canucks use him.
 
Check out http://www.6.7cummins.com (http://www.6.7cummins.com)  Allot of former 5.9 owners there.  Most of them are just damned kids.  LOL
 
 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 28, 2010, 05:55:24 AM
O yeah  A common mistake and problem with buying these trucks.
 
They are supposed to have Load Range E tires.  Not D.  D's will be gone in 10,000 miles.
 
Over all, it looks like a sweet truck Brian (http://www.moparfins.com/forum/smileys/smiley4.gif) (http://www.moparfins.com/forum/smileys/smiley4.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: firedome on March 28, 2010, 06:47:07 AM
That'll make a sweet hauler... Just don't try to park one in Manhattan!!

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 28, 2010, 07:17:00 AM
It's OK Roger. . . .
 
He has a CDL.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Leaburn Patey on March 28, 2010, 11:53:33 AM
...Needs a pistol grip shifter...
Nice truck.
Prospecter package dresses it up on the outside and upgraded interior on the inside.
Older crew cabs are hard to find nowadays.
Loose the redneck exhaust,IMHO
By the looks of a hole in the center of the bed it has served time towing a gooseneck trailer at one time in its life.
It's an 84,but has an 86-to-90 grille in it.
CBarge2010-03-28 16:54:27
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 28, 2010, 05:41:07 PM
I think that's the right Grill Lea.  I had an 84 Ram Charger with that grill in it.
 
I agree on the stacks.  Or at least get rid of the left one.
 
Suggestion.  Go to a 4" exhaust, Turbo back to where ever you want.  I think they make a better boost tube for them too.  Cummins 5.9's need to breath at both ends. 
 
The non-intercooler version was a dog.  The lower you can get the ITT's the better off you are.  It will perform better and lower the EGT's.
 
At the moment, my truck runs almost ambient on the intake side.  The lowest it will go is 32*F.  When it's that low, it doesn't smoke very much.  But it looks like I am going into the 25MPG highway range with the new program I have.
 
You can't use a programmer.  The only ways to get more power and better economy is with injectors, better injector pump, better exhaust, and lower intake temps.  Guys are getting 500 HP out of those, but it's allot of work and money.
 
You're going to enjoy that truck for a long time.  (http://www.moparfins.com/forum/smileys/smiley4.gif) (http://www.moparfins.com/forum/smileys/smiley4.gif) (http://www.moparfins.com/forum/smileys/smiley4.gif)
 
I was thinking about the trans noise you mentioned. . . .Check the carrier bearing on the drive shaft.  Common wear item.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 28, 2010, 08:38:12 PM
Stan...nope not gonna fit in the garage...neighbor and I measured it out at over 21 feet!!(http://www.moparfins.com/forum/smileys/smiley36.gif)

Steve...Thanks for the info, I'll check for the lift pump, but pretty sure I don't have one.  As for an Intercooler, I have been over on another Cummins forum and the 1st Gen guys sometimes use stock ford 7.3 intercoolers.  They can be had fairly cheap and only require a little fab work to make work. 

I will definitely be going Intercooler.  And YES Leaburn the exhaust stacks are going to go ASAP!!  Even a little too redneck even for me. (http://www.moparfins.com/forum/smileys/smiley2.gif)  I'll just be continuing the open 3" exhaust to the back...for now.




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 29, 2010, 06:33:43 AM
Brian
 
You are probably on Cummins Forum.  Frequently refered to as the Dark Side.
 
I'm on www.6.7cummins.com (http://www.6.7cummins.com) with Rockwerks.  Much more civilized, and cleaner info.  Those Damned Kids on the Dark Side will send you down the wrong path allot
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 29, 2010, 07:36:55 AM



Steve I'm over on the DTR.... Diesel Truck Resourse.

http://www.dieseltruckresource.com/ (http://www.dieseltruckresource.com/)


They have forums for  1st, 2nd, 3rd Gen'ers and then all the cummins variations, 12V, 24V, 5.9, 6.7 etc.....seem like a great group of guys and lots of info.

thrashingcows2010-03-29 12:38:24
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 29, 2010, 07:54:20 AM
I'm a member there too, but don't spend very much time there
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Tom Dawson on March 29, 2010, 12:47:18 PM
One very sweet truck, good luck with her, a 2500 HD crew cab Diesel will be my next purchase down the road.
Tom


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Snotty on March 29, 2010, 03:08:26 PM
First year for that grill was '87.  I know, I bought my RamCharger new in '87.  I was able to tell the 87's from the 86's until the '88s came out.  That's the wrong grill for an '84.
 
Also, Brian, is the high-beam switch on the steering stalk?  That steering wheel is simliar to what I had on my '93 Van.  My '84 Fifth Ave. and '87 RC had the same steering wheels, but both were different from what's in this truck and the high beam switch was still on the floor in RCs until '88. 
 
So, unless there is a difference from RCs built in Mexico and trucks built in Canada, someone has made some changes on your truck.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: firedome on March 29, 2010, 03:25:39 PM
I had an '87 Ramcharger too... my daughter totalled it.



Crew cabs are awesome, I had a '72 Cornbinder IH 1 ton crew cab w/ 392
bus engine, for the horse trailer, we traded it on a '78 Dodge 3/4 ton
Extra cab 400V8, or whatever they called the extended cab... it felt
small after the looong IH.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 29, 2010, 04:18:32 PM
I had a 62 Travelall for a short time with a 392 V8 in it also.  It was a 4speed 4 X $.
 
They were great for pulling down out houses, barns, enemies homes. . . .
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 29, 2010, 04:58:52 PM

Quote from: Snotty
First year for that grill was '87.  I know, I bought my RamCharger new in '87.  I was able to tell the 87's from the 86's until the '88s came out.  That's the wrong grill for an '84.
 
Also, Brian, is the high-beam switch on the steering stalk?  That steering wheel is simliar to what I had on my '93 Van.  My '84 Fifth Ave. and '87 RC had the same steering wheels, but both were different from what's in this truck and the high beam switch was still on the floor in RCs until '88. 
 

Yup the high beams are on the steering column.  IOh i know the trucks been messed with, the front seat is out of a mini van or something?  It tilt forward like it was for a 2dr chrysler car...maybe a diplomat or caravelle??

This truck was originally from Texas.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 30, 2010, 08:03:46 PM
So here's the story so far.....

The guy I bought the truck off of got the truck already running and
driving. Basically unchanged from when I brought it home.  He flew into
Iowa and drove the truck home to Kamloops BC.   He then got a call from a
 good friend who needed some financial help so he ended up buying this
friends 85 Crew-cab, long box dually.  So this put RAE beside the house and unused for almost 2 years.

I had been looking for a 1st Gen dodge crew-cab for a while now, and had
 decided that I really wanted a Cummins powered unit.  Well the
crew-cabs alone are hard enough to find due to them being mostly
available to the government, for correction, military, forestry etc.  So
 most eventually ended up in government auctions, but even then a low
production vehicle.

So a month or so ago I decided that I would just buy a 91-93 cummins
powered club cab truck, with a 5 speed manual, since the hunt for a
crew-cab was not going well.  I looked at a few locally but never jumped
 on anything, then a couple weeks ago I happened to come across a diesel
 truck site and was cruising the classifieds when I spotted RAE.  And
when i saw it was diesel powered, and running the NV4500 5 speed I
wanted, and only 3 1/2 hour, 210 miles, away from me I had to go take a
look.

So needless to say I liked what I saw, and went up last weekend and
drove it down.  I did nothing other then top up the tank and drove home.
  I drove 210 miles and used not even a 1/4 tank of fuel!!(http://www.moparnuts.com/forums/images/smilies/giggedy.gif)








Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 30, 2010, 08:04:47 PM










               I pulled the exhaust yesterday.  I had noticed that there was an
exhaust leak at the V-band on the exhaust side of the turbo assembly.  I
 had hoped it was just a band V-band but when I pulled it off I found
that the flange on the exhaust pipe was toast.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1433.jpg)



I spent all day driving around hitting every truck junk yard, diesel
shop and jobber, trying to find this piece.  I can get every other piece
 NEW except this one.(http://www.moparnuts.com/forums/images/smilies/doubt.gif)



I called a guy last night who is parting out a couple 1st Gen trucks and
 he has one I can get in a couple weeks.  So that made me happy.








Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 30, 2010, 08:05:16 PM










               I also pulled the stacks yesterday, and scrapped off the decals in
the rear window. Looks a bunch better.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1427.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1428.jpg)








Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 30, 2010, 08:05:41 PM
Today i installed my class 4 hitch and the rear bumper as well.  Had to
drill one new hole in the frame for the hitch and open up another in the
 hitch.  Now I have to get the trailer wiring worked out as well.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1429.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 30, 2010, 08:06:00 PM
When I was under the truck today I noticed some foam units up inside the
 front of the drivers side box.  I pulled them down and they had nice
openings in the middle, looks like they were used to haul stuff?  No
other reason for them to be up there and in that specific shape?



Did I mention that this truck was originally from Texas....(http://www.moparnuts.com/forums/images/smilies/eusa_shifty.gif)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1432.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1431.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Snotty on March 30, 2010, 08:31:51 PM
You removed the stacks???
 
:-)
 
Had they been two inches smaller in diameter they would have looked cool! 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Stan Paralikis on March 31, 2010, 01:32:43 AM
Those foam boxes weren't used to delliver fresh eggs from the farm...
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 02, 2010, 09:28:11 PM

Quote from: Snotty
You removed the stacks???
 
:-)
 


(http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: 300rag on April 03, 2010, 05:26:32 AM
No more stacks?????????????????  Now it can't be a "Big Red Express"(http://www.moparfins.com/forum/smileys/smiley2.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 10, 2010, 03:54:01 PM

         (http://www.moparnuts.com/forums/images/icons/icon1.gif)







               Oh BTW the truck isn't white, it's a very faded and chalked out
beige.



Here's what it would look like if it was freshly painted...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/84_006.jpg)








Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 10, 2010, 03:54:23 PM
Well finally got some time today to work on the truck.



Since the V-band flange was toast on the original exhaust, I picked up
some used 3" exhaust from a Cummins truck a guy parted out.  Was a good
score for $40!!  Straight pipe, no muffler, and the rear half of the
exhaust was almost new, just dirty and dusty, a few SOS pads later it
looked almost new, the front half was in great shape as well.



So I cleaned and installed everything, using all the clamps, hangers,
and stuff from the two exhaust systems, they were also almost all new
parts as well.  I only had to buy two 3" band clamps for $30.  I then
sold some parts for $40 today, so the whole exhaust system only cost me
$30!!(http://www.moparnuts.com/forums/images/smilies/giggedy.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on April 10, 2010, 04:18:40 PM
Cool
 
That sucker wants to breath
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 26, 2010, 05:37:01 PM
Well I was hoping to get RAE on the road today...but things happened.(http://www.dieseltruckresource.com/dev/images/smilies/frown.gif)



I picked up my 2 piece drive shaft this morning, had to get the front
half shorted a bit since it was pushed TIGHT against the output shaft
seal on the NV4500...Not good. I also had the 2 pieces balanced together
 as well.



I got the drive shafts back in and decided to take RAE around the block.
  Fired it up and gave it some throttle and shifted gears...AND the RPM
didn't come back down, I tapped the throttle thinking something was
stuck, and the throttle went even higher!!  Quickly shut the truck off
and drifted to a stop.  Found out that the throttle shaft was sticky as
all heck.  So off it came, dismantled everything, sanded and cleaned all
 the parts, lubed everything and re-installed...Works great now!!



Then I noticed that the truck wasn't braking right.  Set the
E-brake...Nothing...Hmmm I just adjusted everything up tight I should
have E-brakes.  Brought the truck back into the driveway and jacked it
up, put E-brake on and I could spin the wheel easily.  Had my daughter
hold the brake pedal down to the floor and I tried to spin the rear
wheel...again turned easily.(http://www.dieseltruckresource.com/dev/images/smilies/frown.gif)



So off came the wheels, pulled the axles...another bad thing...they were
 so covered in rust and debris I was absolutely shocked.  I just changed
 the diff fluid, but now I have to drain things again,  clean all the
rust and debris out of the axle tubes and then put everything back
together.  Hope there is no major damage from the previous owners and
myself running this dana 60 with all that debris inside.



I didn't have a socket to fit the 2 1/2" nut that holds the drums and
bearings on so I had to make something work...and no I didn't use a
chisel and hammer... (http://www.dieseltruckresource.com/dev/images/smilies/new1/duhhh.gif)  I used a set of big
flat welding clamps, I was able to grab the side and spin the nut loose,
 but the PO sure used a chisel and hammer though.



Anyway got the drums off and found things unhooked, one bad drum, one
set of brake pads that are turning all soft and flaky, never seen this
before?  So tomorrow I go shopping for proper socket for the axle nut,
drums, and shoes, seals etc....$$$



Sorry for the long winded post...(http://www.dieseltruckresource.com/dev/images/smilies/redface.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on April 26, 2010, 06:09:32 PM
Hey Bri
 
Take a couple of clicks for us so I can see what you are talking about.
 
Think about those wheel cylinders too.  May as well.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 26, 2010, 09:17:01 PM

I'll grab some pics tomorrow.  BTW This is a full floating Dana 60.

Been reading and researching all evening and I think I will be heading across the line to NAPA, since they seem to have new drums and riveted shoes for a reasonable price.  And with the CDN dollar at par it just makes good financial sense...(http://www.moparfins.com/forum/smileys/smiley4.gif)

Oh and the wheel cylinders are new.  They just didn't replace or repair anything else.(http://www.moparfins.com/forum/smileys/smiley36.gif)

thrashingcows2010-04-27 02:18:09
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on May 10, 2010, 12:20:46 PM












               Well RAE is on the road, almost a week now, and I'm lovin' it!!(http://www.moparnuts.com/forums/images/smilies/giggedy.gif)



All the servicing is done now.  Rear end is all done, getting all the
rust and crud out of those axle tubes was a major pain!!  But they were
almost spotless when I put it all back together.  New drums and shoes,
serviced all the E-brake and brake hardware and everything works great
now.



Serviced the front rotors, cleaned and repacked the bearings, new seals,
 and had to cut through all the nasty glazing on the rotor surface by
hand, but way better braking now.



Think the throw out bearing is going, squeals once in a while when
engaging/disengaging the clutch.  So the tranny will have to come out
since it's a sealed bearing and there is no access to the clutch or
offending areas.(http://www.moparnuts.com/forums/images/smilies/doubt.gif)



But I've put on almost 325miles and used maybe 10 gallons of fuel....(http://www.moparnuts.com/forums/images/smilies/22_yikes.gif)  That is mixed Hwy
 and city.  It got 42 miles to the gallon when I drove it home on the
initial purchase.  Compared to the 360 which was getting maybe 300+
miles to 30 gallons.



Just bought a Tach and Pyro kit for it, with a dual pillar gauge pod,
not cheap but necessary.  Will get a boost gauge as well once I get an
intercooler set-up on.



Sure nice to be able to haul the entire family in the truck now.  Hope
to use RAE for our family vacation this year, but need to do a retro on
the A/C system first.







Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on May 10, 2010, 12:54:55 PM
If you look around, you should be able to find a factory dash with the controls heater/Evaporator assembly, pretty cheap.  Does that engine have a vacuum pump on it?  If so, you have it made.  If you tird to hook to the intake, that engine will swallow the cab. (http://www.moparfins.com/forum/smileys/smiley2.gif)
 
I'll have those intercooler demensions for you in a day or so.  That would be a nice adder.  Probably good for 2 more MPG.
 
That's great mileage for a stick.  Are you sure the Odometer is accurate?  Sounds very high
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on May 11, 2010, 07:23:46 AM

Quote from: POLARACO
 
I'll have those intercooler demensions for you in a day or so.  That would be a nice adder.  Probably good for 2 more MPG.
 

No rush on the IC deminsions, but I appreciate it.

As for the mileage...who knows.  We all know the top half of the tank is bigger then the lower half so that could be throwing things off.  As well the speedo could be off too, will have to get the wife to pace me in her car and check the speedo and Odo.  But even if the numbers are higher then they should be it's still getting WAY BETTER mileage then the old gasser in the old 3/4 ton dodge.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on May 11, 2010, 07:26:36 AM
No arguement.
 
You have a portable GPS?  You can clock it with that too.
 
Maybe it has a really tall rear in it?  Not sure of the ration, but typically, sticks a 4.11's or 3.40's?
 
Maybe you are lucky or everything is all down hill there. (http://www.moparfins.com/forum/smileys/smiley2.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on May 11, 2010, 08:50:39 PM

Quote from: POLARACO
No arguement.
 
You have a portable GPS?  You can clock it with that too.
 
Maybe it has a really tall rear in it?  Not sure of the ration, but typically, sticks a 4.11's or 3.40's?
 

Portable GPS...Man I abhor those things.  Wouldn't personally own one but might be able to borrow one for a day.

The rear gear is 3.54, Dana 60.  But need new tires, thinking of getting some 235/85/16, BF Goodrich Commercial TA's from Tirerack.com.  Great prices, and better then anything I can find locally, here in Canada and the US.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on May 12, 2010, 06:41:09 AM
Hold up on that. . . . .
 
Look at the Firestones.   Really nice all around tread design.  The last set, which was not messed with by human hands, (Long Story) went to 70,000 miles and were still serviceable, but not 4 wheel drive good, tread wise.  I forget the name on the ones I have now. . .
 
I just bought a set of 285/17's, 10 Ply,  mounted and balanced for less than $1000, US.  The Goodrich are 500 more.
 
Also, I got a better deal locally than from Tire Rack.  Check it out.   My Dodge Stealership was the best price.  That worked out because my tires needed to be programmed to the truck.  Remember, you have to pay shipping which is more than the cost to mount and balance (http://www.moparfins.com/forum/smileys/smiley36.gif)
 
This is the third truck I have installed these tires on. . .   The ones I have are a newer design.  They stick like glue, have a good roll efficiency, ride real good, and, as said, wear like iron.  Hard to get all that in a tire.  Not knocking the other brands, it's $$$$ and these have out performed any others.
 
POLARACO2010-05-12 11:42:33
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on May 12, 2010, 07:12:53 PM
Thanks for the advice Steve, but I researched everything last night, and decided on the BFG's I stated above. 

I priced out things locally and they were going to be huge money!!  I ended up getting the set off E-bay for $484 plus $95 shipping., Tirerack.com was going to be $525 plus $114 shipping.   This is almost half price what the local shops wanted for the same tires.  Will cost be about another $75 to mount and balnce so I'm still coming out way ahead on this one.

Now I need a new power steering box, leaking pretty bad.  And the motor needs a valve adjustment as well, doing that next week.  Also the throw out bearing seems to squeal every so often when engaging/disengaging the clutch.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on May 24, 2010, 08:55:32 PM
Well speedo is out by about 10mph, guess my speedo gear in the NV4500 is
 set for a 4.10, not a 3.54 rear.  SO that will throw off my MPG a bit,
but even cutting off 10% of my total mileage I'll still be around 600+
miles on my fill up in a day or two.



I have my new 235/85/16 BF Goodrich commercial T/A tires on, nice tires.
  I also got my new flex brake hoses installed today as well.



I've ordered all the pieces to retro my A/C system under the hood, and
I'm not using any of the original parts other then the compressor, and a
 new Expansion valve, other then that everything will be new or retro'd.



Found out my upper ball joints and inner tie rods are on the way out.
But the parts truck I had last year had new upper control arms in the
cab, new Moog BJ's and new bushings, so that costs me NADA...(http://www.moparnuts.com/forums/images/smilies/happy.gif)  I'm going to order new inner and
 out tie rods as well.  Might replace the lower BJ's since I'll have
everything apart anyway.



Need to find and original tranny cross member, since the C-channel they
used to make the mounts are a little lacking, there is only one bolt on
either side to hold the mount to the frame!  Wonder what would happen if
 I loaded the drive line up....(http://www.moparnuts.com/forums/images/smilies/eusa_doh.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on May 24, 2010, 08:56:08 PM
I've also picked up a front seat from a 94-98 2nd Gen dodge ram.  I
really like having the armrest and dual sliding seats, for his and her
comfort. (http://www.moparnuts.com/forums/images/smilies/happy.gif)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1555.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1554.jpg)



I'll have to redo the floor mount brackets and tracks to get it to sit
as low as possible, one of the draw backs to being 6'8"...(http://www.moparnuts.com/forums/images/smilies/wink.gif)  But should be able to knock that
 out in a day, with a little grunt help from my neighbor.




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 06, 2010, 04:57:11 PM
Well I've been continuing my work on RAE.  I installed the new power
steering box last week.  The old one was leaking from the input shaft,
and main steering shaft seals.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1606.jpg)



Much better not having the puddle under the truck every time I park.



But had to flush the system a whole bunch.  I grabbed some PS fluid I
had laying around and didn't bother to check it and just dumped it in.
Well it wasn't until i turned the truck on and started cycling to get
the air out I noticed a foul smell and lots of foam in the system.
Turns out the fluid was contaminated with water, smelled horrible and
was a murky orange color.  So up to the store and buy some fresh fluid,
then drain, cycle system, drain and repeat.  Still a little bit left in
the system but not bad.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 06, 2010, 04:58:54 PM
Well I decided to change  the fluid and install a filter kit from
Geno's.



I got my Syntorq from, www.blumenthalmfg.com (http://www.blumenthalmfg.com/) for 5 quarts it cost me $59,
not a bad price!!    Considering the local Chrysler dealer wants $30 a
quart!!



So I removed both PTO covers and did the complete clean out, wiped the
inside of the case, sides and bottom until it was as clean as I could
get it.  Then installed the filter kit on the pass. side and refilled
with the new syntorq.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1632.jpg)



I noticed it shifts a little smoother, and it doesn't grumble quite as
much.  But before I did this I noticed that it didn't grumble as much in
  the mornings when the fluid was cool, once it warmed up the grumbling
 became much worse.  So hopefully it will help, but at a minimum I at
least know have the peace of mind knowing the condition of the fluid in
 the tranny.



Another thing that I noticed when I pulled the PTO covers was that both
 the side covers had a fair amount of scratches and gouges on the
inside.   I think this tranny might have blown before.  So who knows how
 old the  tranny rebuild is but my input shaft cover seal is weeping a
bit.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1629.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on June 07, 2010, 06:37:29 AM
Stick a magnet on the filter.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on June 07, 2010, 06:37:54 AM
I have to measure that intercooler for you.  You still interested?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 07, 2010, 07:55:08 AM

Quote from: POLARACO
I have to measure that intercooler for you.  You still interested?

No I don't think it will work for me., but appreciate you keeping me in mind Steve.

I'm also working on doing a complete A/C retro fit, same set-up as I used on the wagon.   I plan on using an aftermarket universal intercooler so I can keep my current grille.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 15, 2010, 11:09:31 AM
Well got off work friday evening and went  to my truck, fired right up,
1/2 crank as always, and I let it idle for  a couple minutes but it
seemed to have a stumble, like a miss fire?



Put the truck in gear, and started to drive off but again it was
stumbling.  Got to the exit and it stummbled hard and died.  I tried to
 fire it up again and it fired briefely and died again almost
immediately.



I pushed it back out of the way and popped the hood.  The "New" lift
pump I installed a few weeks back was leaking.  I tried to prime the
system but the pump wouldn't draw any fuel.  I had the wife bring down
the old one I removed, it leaked but would still prime.  So installed
the old lift pump and primed the system, then tried to fire it again,
nothing.  Cranked it a bit, still nothing.  So had to get a hook to drag
  old RAE home.(http://www.dieseltruckresource.com/dev/images/smilies/frown.gif)



My injection pump has been leaking from all over the place, was going to
  order a reseal kit and reseal it.



I worked on it yesterday, and, Well it's running again....for now at
least.



I decided to crack the injectors, don't think they had been loosened
since it left the factory.  I only had fuel at #1, #4, and #6, #2 was
bone dry, and the others only had a trace of fuel in the injector head.
  Cranked it and started getting fuel squirting out at all the
injectors,  tightened them down and then fired it up.



It ran rough for the first minute or so, I brought the RPM's up, lots of
  smoke, white in color, then it slowly cleared up.  Seems to be OK for
 now, but I think I will transfer the plates to my 87 ram gasser unit
until I  can get a piston pump, and rebuild the injection pump.  Don't
feel like  any more tow bills....(http://www.dieseltruckresource.com/dev/images/smilies/wink.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 15, 2010, 11:10:15 AM
Since it's off the road for a couple weeks I've decided to fix a few
more things as well.  I adjusted my valves last night, and picked up
some new valve cover gaskets, remember cummins have 6...(http://www.moparnuts.com/forums/images/smilies/happy.gif)  Also going to install new upper
control arm bushings and ball joints, new inner and outer tie rods as
well.  And try and finish up my A/C retrofit.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on June 15, 2010, 03:51:34 PM
Try using an Air Dog.   You can eliminate the factory filter if you want.
 
Those Bosch pumps are nutorious for leaking.
 
If those cylinders were dry, I'd ne worried about the cylinders.  Remember, the cylinders depend on that fuel to lube.  Maybe it's time for new injectors?
 
Read about the air dog at www.rollinsmokediesel.com (http://www.rollinsmokediesel.com)
 
 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 18, 2010, 10:00:40 PM

 
If those cylinders were dry, I'd ne worried about the cylinders.  Remember, the cylinders depend on that fuel to lube.  Maybe it's time for new injectors?
 
[/QUOTE]

Only reason they were dry was due to the air the VE pump sucked in.  So they hadn't been running dry.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 29, 2010, 04:43:58 PM
Update....



Well it's all back together now.  Here's what was done to get around the
 differences in the gasser vs diesel center link and tie rod ends sizes.



I ordered all new tie rods, two diesel inner tie rods, and two gasser
outer.  Here is a pair of the new ones.  You can see the difference!!



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1720.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1721.jpg)



So to get around having to find a set of diesel lower ball joint arms
and such, I decided to have the big diesel tie rods machined down to fit
 the gasser adjustment sleeve, and therefore have the proper size end
and tapper to fit the diesel center link.



I found a local guy who works out of his back yard.  I brought him in
one of the old used gasser inner tie rod and adjustment sleeve, and the
two diesel units.   He then milled down the shaft size and threaded
them, Left hand thread of course.  He said the hardest part was figuring
 out how to mount the tie rods in the milling machine since the odd
shaped tie rod head was too big for his chucks.  He ended up having to
pin them on each side, center them, then mill them down, then thread
them, then cut them to size.



Diesel and gasser tie rods.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1731.jpg)



And them assembled in the sleeve.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1732.jpg)



And now mounted in the truck.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1733.jpg)



I have also redone my upper control arms, so after the VE pump is
re-sealed, new piston pump installed, new fuel heater and lines, I will
get the front end realigned.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on June 29, 2010, 04:51:47 PM
I may be wrong on this Brian, but I can call if you want. . . .
 
That front end is probably a 1 ton suspension and steering.  Isn't that a 250?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 29, 2010, 05:18:53 PM
No the truck is was a gasser 84 D350, so 1 Ton, with the 4000lb front end as well.  They didn't start running those HUGE tie rods until the cummins in 89. 

I didn't have the time, or funds right now to locate adn install all the diesel front end components.  I will be picking those up and installing them later.  This is just a temperary fix to get RAE back on the road, and have things safer then they were.  They may not last 20K miles but long enough to get the parts I need and get them installed.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on June 29, 2010, 06:06:09 PM
It took them that long?
 
POLARACO2010-06-29 23:06:30
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on June 29, 2010, 06:07:08 PM
What do you want to bet the 2nd generation used the same parts?  I mean in the 2 wheel drive.
 
POLARACO2010-06-29 23:07:56
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 29, 2010, 06:59:33 PM
The diesel tie rods and even the adjustment sleeve parts are readily available, it's the diesel lower ball joint/steering knuckle (not sure is that is the right term) that is the hard part to get.  I need to find a 2wd diesel from 89-93 to get those parts from.




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on June 30, 2010, 06:10:08 AM
let me call my dealer parts guy and see what he says.  He was dishing out parts back then too
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 22, 2010, 10:35:15 PM
Well I've been having all kinds of fun.  My "off the road for a couple weeks" is turning into a lot longer then that....(http://www.moparnuts.com/forums/images/smilies/doubt.gif)



My injection pump re-seal seemed to go OK, no problems really, but after
 I got it all back together the truck would not fire.  I tried for 3-4
days and could not get more then a sputter out of it.  The guys on my
cuumins diesel board have been giving me all kinds of help and advice,
but it just won't fire.



I have since pulled the injection pump out again, and I'm going to tear
it down because I found a bunch of metal shavings in the bottom of the
pump.  Those shavings were not there before.  So something is not right.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 22, 2010, 10:35:35 PM
Well since I'm retrofitting my A/C system...all new, no factory parts
under the hood other then the compressor...will do a update when
complete. (http://www.dieseltruckresource.com/dev/images/smilies/wink.gif)



Anyway I needed to use the space where the radiator overflow tank is
currently placed.  Also I will be running the tubes for the IC one day
through this area as well, and the BHAF too. (http://www.dieseltruckresource.com/dev/images/smilies/smile.gif)



So this is the factory set-up...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1784.jpg)



And this is where I decided to put the new overflow tank, behind the battery.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1785.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 22, 2010, 10:36:13 PM
But before I could do any of this I had to figure out what kind of tank I
 was going to use.  I spent a couple days in the wrecking yard and
couldn't find anything that would work.  SO one evening I was sitting
thinking about things when it occurred to me that I already had the
perfect unit, it was on my 68 Chrysler T/C wagon...but it is a washer
fluid reservoir, not an over flow tank, but I can make it work.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1789.jpg)



So onto E-bay I went and found a tank for a 65/66 C-body (Newport, New
yorker, Monaco, Polara) This tank is slightly different then the one on
my wagon, since the pump is not attached to the tank, it's a remote
unit.  So therefore the tank just has a small spigot, not the big hole
to mount a washer fluid pump.  Much better for my plans.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1788.jpg)



I just used a vacuum plug and a small zip strap to secure it nice and tight.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 22, 2010, 10:36:49 PM
Now came the positioning of the tank.  Since it needs to mount on a
flush surface I decide to cut a notch out of the inside of the fender.
But first I had to relocate one of the horns just down the way.



I lined up the tank then marked off the area I needed to cut out.  Used
my handy dandy dremel and a few cut off blades and out it came.  Dressed
 up the sharp edges with a fine flat file



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1787.jpg)



Then I used a pencil to mark where I needed to drill the mounting holes.
  Had to use a fat washer behind the mounting area since I didn't get my
 cut perfectly flush...not a biggie.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1791.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 22, 2010, 10:37:25 PM
Now came the fun part.  Since this was a washer fluid unit it obviously
doesn't have the overflow design built into it.  I over came this with
another wrecking yard run and an overflow cap from a late 90's Plymouth
Sundance I think?



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1793.jpg)



Unfortunately the cap was too small to fit the new tank so I had to get
creative.  So I looked at the design and figured I could make it fit on
top of the factory cap.



So first I needed to drill a big hole for the main line going into the
tank, then I drilled a smaller hole just to the side for the over flow.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1794.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1795.jpg)



I then secured the over flow cap, with it's original gasket as well, to
the new cap with a pal/speed nut.  I found this in my tin of speed/pal
nuts for cars I parted over the years.  But I'm sure you could find one
at the parts store.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1796.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 22, 2010, 10:38:05 PM
Now I had to run the hoses.  The one inside the tank was shaped perfect,
 just had to cut off about 3-4" and with the S-curve in the hose it
dropped over perfectly to the deepest side of the tank.  The outflow
hose tucked up nicely to the side.  The hardest part was trying to get
the hose connected to the rad since the nipple off the rad points in the
 opposite direction.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1799.jpg)



I managed to make an old vacuum fitting work, I needed a 180* unit and
didn't have time to run up to the parts store and see if they had one or
 not.  So once I got that sorted out I secured the main hose with a
couple zip straps and an old wire holder.  I think it turned out OK, and
 I still have lots of room for my big 1000 crank amp battery I have in
there now.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1800.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1801.jpg)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Stan Paralikis on July 23, 2010, 02:33:59 AM
I love when a little "engine-nuity" comes up with a slick solution.  Good job. (http://www.moparfins.com/forum/smileys/smiley4.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 23, 2010, 08:37:09 AM

Quote from: Commando1
I love when a little "engine-nuity" comes up with a slick solution.  Good job. (http://www.moparfins.com/forum/smileys/smiley4.gif)

Thanks Stan.....and it's still all mopar as well.....(http://www.moparfins.com/forum/smileys/smiley4.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on July 24, 2010, 06:05:20 AM
Brian
 
That only has one battery?  Wait until winter
 
Looks like you are completing the conversion the right way
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 24, 2010, 02:00:41 PM

Quote from: POLARACO
Brian
 
That only has one battery?  Wait until winter
 

I'll keep it plugged in in the winter so I hope to have no issue with it starting.  That is my old battery, I just bought a new 1000 cranking amp unit, 850 amps below freezing.....I could always get one of the battery warmers I found on the wife's 02 Concorde...factory set-up hooked through the block warmer line as well.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on July 24, 2010, 05:10:07 PM
Yeah OK, that's when you are home.  What about work when you are being a Bean delivery boy?  Mannnn  you can't be late with deliveries to Hortons. . . .   LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 24, 2010, 06:07:54 PM

Quote from: POLARACO
Yeah OK, that's when you are home.  What about work when you are being a Bean delivery boy?  Mannnn  you can't be late with deliveries to Hortons. . . .   LOL

Yeah I've thought about that as well....I think there is a plug in not too far away, might have to carry a 100' ext chord to plug it in when I get back to the yard.  I'm usually about an hour before I get my trailers parked and all my paper work done, so it would at least give it a bit of warmth before I try starting it.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 09, 2010, 09:03:07 PM
Well thought I'd update things....



I pulled the Injection pump after I couldn't get it to fire, and I had
spotted metal pieces in the pump when I had the top off to inspect other
 things...not good!!



So I pulled apart the pump the other day to inspect things.  Here's what I found.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1816.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1815.jpg)



That is supposed to be a hardened steel washer.  When I had the pump
apart to reseal things, I guess the washer dropped out of place and got
jammed up where it shouldn't have been.  The is a lot of spring pressure
 and torque through this area while generating the PSI required for the
diesel injection.  So one thing led to another and the washer shattered,
 it also cracked the head on the injection piston.



This is what it's supposed to look like, the washer that is.  And you can see where it supposed to sit inside the piston head.



(http://i290.photobucket.com/albums/ll276/1stGen545/HPIM1290.jpg)



So I'm going to talk to the local diesel injection shop here tomorrow
and find out what they figure it will cost to replace the broken pieces
and then rebuild the pump.  Turning into an expensive mistake...oh well
lessons learned, not cheaply, but learned none the less.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 10, 2010, 05:15:01 AM
Yeah. . .But look at all the fun you'll have later.  Rust proof that truck and it will last forever
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 18, 2010, 01:13:44 PM
Turns out the pump is toast, well parts are toast and not repairable or easily replaced.

The above pic of the washer adn piston head with keyway, well that piston head in mine cracked when the washer shattered.  I was cleanign and rebuilding everything when I noticed the hairline cracks.(http://www.moparfins.com/forum/smileys/smiley36.gif)

The local shop quoted me $1400 for a reman unit, or about $1600-$1800 to rebuild and fix mine.  So I did some searching in craigslist and found a guy with one down in Tacoma WA.  He wanted $150 for a nice unit he pulled form another 89 motor, and mine is an 89 as well!!  So Monday night after the wife got home I drove the 3 hours one way to pick it up, and then another 3 hours home.  Well worth the travel.  I'm currently working on resealing this one and hope to have it in the hole by this weekend, and if karma is with me running not long after.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 18, 2010, 01:13:57 PM
I worked a bit over the weekend on getting the frame built for my 2nd gen 40/20/40 seat.



(http://i697.photobucket.com/albums/vv340/thrashingcows/PICT1553.jpg)



With me being 6'8" and 275lbs I wanted the seat as low as possible and
set back to give me lots of leg room.  I have read almost every thread I
 could find here on the DTR related to this subject, and decided,
especially after I got my seat, that I wasn't going to use the factory
2nd gen seat tracks and brackets.



So I spent a fair amount of time trying to figure out what I wanted to
do.  Eventually I decide that I would do away with the dual tracks and
make a solid bench seat style set-up.  I also decided that I wanted to
use that factory bench seat tracks.



I then took all the measurements from the 2nd gen seat, pulled the stock
 bench out, but took tons of measurement, and then spent some time with a
 pen and paper drawing up several different ideas on how to attack the
situation.



I decide that I would build the frame out of 1" square tubing, 1/8th
wall, but wasn't sure exactly how things would work out in real life,
since ideas and drawing can't always predict everything.  So I came to
the decision that I would build the frame, initially, from wood since
it's cheap and easy to work with.  So out came the table saw, and some
2x2's I had around, and I ripped me a bunch of 1"x1" wood.  I then
started cutting and then used my finishing nailer to piece it all
together.



So after a few hours I think I have a final design, I had to modify it
several times from my original drawings and ideas, the tranny tunnel for
 the transfer case posed the biggest problem.



Here are some current pics of the project....



(http://i697.photobucket.com/albums/vv340/thrashingcows/PICT1859.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/PICT1860.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/PICT1861.jpg)



Now I just need to build it from steel.  Will update when I get it built and the new seat installed.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 18, 2010, 05:21:14 PM
I believe Stan said Engine-uity.  (http://www.moparfins.com/forum/smileys/smiley4.gif)
 
(http://www.moparfins.com/forum/smileys/smiley9.gif)
 
Lookin real good
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 18, 2010, 05:37:58 PM

Quote from: POLARACO
I believe Stan said Engine-uity.  (http://www.moparfins.com/forum/smileys/smiley4.gif)
 
(http://www.moparfins.com/forum/smileys/smiley9.gif)
 

Thanks Steve....(http://www.moparfins.com/forum/smileys/smiley4.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Jason Goldsack on August 19, 2010, 01:38:03 AM
Great Project.. I really miss my Gen 1 Cummins.. I put 250 000 km on mine over 10 years and it always started even in the dead of winter..

When the body was shot and the pump let go I sold it...




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 21, 2010, 06:27:29 PM
Well ol' RAE is alive...again!!!!



After 2 months, and one bungled re-seal and a broken pump later, and
then a replacement pump and re-seal, ...I got ol' RAE running this
evening!!!(http://www.dieseltruckresource.com/dev/images/smilies/biggrin.gif)

I resealed the replacement IP I got, installed it and hooked everything
 up and between 15-20 cranks, prime the injectors, then it quickly
rattled to life!!



I'll have to figure out the timing since when I installed the pump the
marks were way off.  Comparing the original mark to the replacement pump
  they were darn close, probably within 1/16th.  When I installed the
new  pump it was probably 1/4" or more below the original mark on the
case.   So I brought the pump up even with the mark on the case, to at
least  get it close.



I`m one happy camper tonight!!(http://www.moparnuts.com/forums/images/smilies/giggedy.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 22, 2010, 04:53:34 AM
Too advanced and it will be hard to start, but get great mileage and power.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 22, 2010, 08:08:15 PM

Quote from: POLARACO
Too advanced and it will be hard to start, but get great mileage and power.

What about not enough advance?  I think I have the pump set about 1/16th to a 1/8th less advance then the original pump.  Starts real easy though.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 23, 2010, 04:43:34 AM
Yep. . .  It will probably be weak. 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 24, 2010, 02:32:40 PM
Well since I got old RAE up and running I've started to hear a tin type
rattle coming from the front of the motor.  I got on my old stethoscope
with metal tube on the end and started listening around the motor.  It
is most definitely coming from the timing case.




When I pulled the original IP to reseal it I decided to do my KDP as
well, so I had the timing cover off.  I didn't mess with anything else
inside the case other then the KDP and obviously the loose IP gear.  Now
 with the new IP I now have this major rattle.  I popped off the oil
filler tube to see if I could see if the snout on the IP was wobbling,
it's nice and tight.  But with the oil filler tube off it's a lot
noisier and I can distinctly hear it at 20-30 feet.





When I had the IP apart for the reseal I checked the front bushing, no
visible wear and the shaft was tight so I don't think this is my
problem.  I was thinking about it and I wonder if the key on the IP
shaft is partially hung up and the gear is not sitting all the way back
on the shaft like it should be? So then cause there to be an odd lash on
 the gear? Or what about timing?  If I don't have enough would that
cause the gears to rattle like that?  I have read here on the DTR about
running too much timing and the motor sounds like the old chevy 6.2/6.5
diesels, mine does not sound like that, it sounds great, other ten this
new tin type sound.





I just can't get a break....:(

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 24, 2010, 09:14:49 PM
I recall there was a pin yjay used to shear in those.  Had something to do with the timing gear.  I forget exactly what is was, but there are upgrade kits to repair it.  Maybe that's what you are hearing.  Could be ready to dump on you.
 
POLARACO2010-08-25 02:16:01
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Snotty on August 25, 2010, 09:19:41 AM
Brian, my '87 360 4-speed RamCharger that I purchased new had the same sound from day one.  I never found it, but 79,000+ miles later when I sold it, the sound was still there and I never had a problem.  I chalked it up to the heat-riser, but never knew for sure.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 27, 2010, 09:28:50 PM
There was no noise like this before I swapped out the IP.  The guys over on the DTR diesel site I frequent think the timing gear  has got hung up on the woodruff key on the IP shaft.  I'm leaning towards that as well, since this would throw off the gear mesh and allow a lot more slop in the gears. 

I got the fan and shroud and stuff torn off before I went out of town for work, just got home, but will pull the timing cover tomorrow and check things out.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 29, 2010, 08:56:45 PM
That's what I was talking about.  There's a upgrade kit available.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 07, 2010, 06:51:33 PM
Well I've had the front of the motor apart several times checking
everything.  The timing gear on the IP was not square on the shaft so I
pulled the gear and relined up the shaft and gear again, properly this
time.  I thought this was my noise...nope still there!!  So I tried
running it with no belt, still got the noise.  My next is to pull the
vacuum pump/power steering set-up, someone suggested that the bearing
might be going.

So next week I'll do this and see if I still have Mr. noise.








Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 07, 2010, 06:52:01 PM
OK I'm going to post all this in one thread so others can follow from start to finish in one place.



Here's a rehash of my other thread...Aug 17/10



    Quote:

                                      I worked a bit over the weekend on getting the frame built for my 2nd gen 40/20/40 seat.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1553.jpg)



With me being 6'8" and 275lbs I wanted the seat as low as possible and
set back to give me lots of leg room. I have read almost every thread I
 could find here on the DTR related to this subject, and decided,
especially after I got my seat, that I wasn't going to use the factory
2nd gen seat tracks and brackets.



So I spent a fair amount of time trying to figure out what I wanted to
do. Eventually I decide that I would do away with the dual tracks and
make a solid bench seat style set-up. I also decided that I wanted to
use that factory bench seat tracks.



I then took all the measurements from the 2nd gen seat, pulled the stock
  bench out, but took tons of measurement, and then spent some time with
 a  pen and paper drawing up several different ideas on how to attack
the  situation.



I decide that I would build the frame out of 1" square tubing, 1/8th
wall, but wasn't sure exactly how things would work out in real life,
since ideas and drawing can't always predict everything. So I came to
the decision that I would build the frame, initially, from wood since
it's cheap and easy to work with. So out came the table saw, and some
2x2's I had around, and I ripped me a bunch of 1"x1" wood. I then
started cutting and then used my finishing nailer to piece it all
together.



So after a few hours I think I have a final design, I had to modify it
several times from my original drawings and ideas, the tranny tunnel for
  the transfer case posed the biggest problem.



Here are some current pics of the project....



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1859.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1860.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1861.jpg)



Now I just need to build it from steel. Will update when I get it built and the new seat installed.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 07, 2010, 06:52:29 PM
So the I built the frame out of steel.  1" square tubing by 1/8" wall.
 The holes I drilled at 7/16 for the 40/20/40 seat and then 1/2" to
mount  ot the original bracket.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1910.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1911.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1912.jpg)



And someone asked if I could post all the measurements and such in a
drawing.  I did one up in paint works last night.  Not to scale but
shoul dhave all the info for others to build there own.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/2ndgenseatbracket.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 07, 2010, 06:52:49 PM
Next came the trial fit. I mounted everything on the frame, with only
tack welds to hold it together.  Then put it in the truck with the help
 of my neighbor.

It went in no problem and everything looked good.  I had to also drill 2
  new holes in the buddy seat since the frame did not extended to pick
up  the 2 rear mounts.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1909.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1908.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 07, 2010, 06:53:30 PM
I ordered some special fasteners to secure the frame to the stock bench
 brackets, but they didn't arrive in time so I decided to make my own.  I
  needed a deep socket type fastener to go down into the 1" tubing and
fasten to the stock 5/16 NC thread stud.



Here's what I did.



Bought four 5/16" joiners, taped them off leaving just under 1" of metal showing.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1913.jpg)



Then used my air sander to round off the exposed end to just under 1/2"



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1914.jpg)



Once that was done rummaged through my tin of washers to find 4 that would work.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1915.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1916.jpg)



Then i had to figure out how to hold the washers secure and level while I
  tacked them in place with the welder.  I have a few small but strong
magnets and these did the job.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1917.jpg)



Few minutes with the welder and I was done.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1918.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 07, 2010, 06:54:15 PM
Here you can see how the new fasteners work.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1919.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1920.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1922.jpg)



Only problem I found was when I was doing my final install the rear
fastener was too tall and was hitting the padding and would have dug
into the seal when I sat in it.  So I trimmed it down.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1925.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 07, 2010, 06:54:42 PM
So here's the last trial fit before I started to install the seat.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1923.jpg)



So the buddy seat had to go on first before the bracket went into the
truck.  No room to get the bolts up and under the new bracket.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1924.jpg)



Here's a couple shots of the bracket bolted to the seats, from down low.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1929.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1930.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 07, 2010, 06:55:08 PM
And the final install, all done!!!



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1928.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1932.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1931.jpg)



So I sat in the seat and there is a ton of head room, and lots of leg room!


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 07, 2010, 07:52:44 PM
Hell. . .anyone can set a seat in a truckand take a picture.  LOL 
 
 
 
 
 
Good Job.  Looks great and those seats are comfey
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 10, 2010, 10:03:22 PM
Thanks Steve!!

Yup that seat is way more comfortable then the old, crushed and collapsing bench seat that was in there.

I'm going to eventually switch the interior over to black and gray, since it's just a mish-mash now...brown dash with red parts, red trim, beige door panels and now a gray seat....not pretty but works...kind of like all of us.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 11, 2010, 07:35:48 AM
I see the Solar Charger.  I use one too.  My truck can sit for weeks at a time.   With the pooter in it, always warm. . . .
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 11, 2010, 12:13:57 PM

Quote from: POLARACO
I see the Solar Charger.  I use one too.  My truck can sit for weeks at a time.   With the pooter in it, always warm. . . .

Yeah handy little item, keeps the battery fresh and fully charged.  And other then the initial cost, cheap to run....(http://www.moparfins.com/forum/smileys/smiley4.gif) 

Heck it even charges with indoor lighting as well, so if you have a car in storage you can use one of these to kee the battery fresh.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 11, 2010, 01:13:29 PM
Yep.  I have several.  Left alone, it will charge a dead battery.  I have one in Polaraco
 
If you guys get one, make sure you get one with a Diode in it.  The can discharge batteries when it's dark.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 12, 2010, 12:15:49 PM
Well yesterday I decided to pull the vacuum/power steering pump
assembly.  If you don't know they are a two piece unit that is attached
and then drives off a gear in the timing case.



Got the pump assembly out and fired the motor up, no more noise!  But I
could still hear a slight ding in the gear train after my KSB cut out.
What the KSB does is advance the timing some and increase the fuel
pressure during a 1-2 minute warm up cycle.  SO I thought maybe my
injection pump (IP) timing was retarded to far.



SO today, in the pouring rain I might add, I advanced my IP timing by
about 1/8th inch.  What a big difference!  The motor is was more
responsive and just sounds better all the way around.  Also the slight
dinging I could hear in the gear train was now gone.  I was running the
motor with no KSB as well.



I then thought maybe I should double check the vacuum pump assembly and see if the noise would now be gone.



Re-installed the vacuum/power steering set-up.  Got  it in a fired it
up, rattled like before for a couple minutes then got  quiet.  I was
thinking I got it all sorted out and was pretty pleased  with myself,
but had a sneaky suspicion and thought I'd let it idle for a  few more
minutes.  The noise came back...but definitely not as loud.  I  can hear
 it but it is not as noticeable.  My guess is the noise was  there
before my whole fiasco with my IP and I just couldn't hear it.   Now
that I know what the noise is, and can pick it out of the other  engine
noises, I can hear it.



I'm guessing the timing was retarded too much with the new IP and was
allowing the gear train to have a little more "slop"? or what ever you
want to call it.  So I will definitely have to replace the vacuum/power
 steering pump assembly

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 13, 2010, 06:23:13 AM
Try advancing it again, this time a 16th.
 
POLARACO2010-09-13 11:23:40
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 13, 2010, 07:26:42 AM

Quote from: POLARACO
Try advancing it again, this time a 16th.
 

What is this magnetic timing tool you speak of????

That's one of the thinks I don't like about the Cummins, is the lack of a visible timing set-up.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 13, 2010, 07:30:22 AM
It is a magnetic pickup which goes into a slot near the damper on the left front.  Then is somehow reads the timing of the pump.  I forget how it works now.  It's been so long.

You might be able to get a used one POLARACO2010-09-13 13:07:42
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 08, 2010, 05:42:50 PM
Thought I'd share some pics and info on how things went....



Well I left Saturday morning at 9am to go get my 48 Desoto from Tigard
OR.   Went down bare, no trailer, took me about 6 hours to get there.
Was cruising at approx 65 mph, in 5th gear, 1750-1800 rpm and about 2lbs
 boost.  Went 400 miles on 15 gallons...that's 26.6 mpg. (http://www.dieseltruckresource.com/dev/images/smilies/smile.gif)



Picked up the U-Haul trailer Sunday morning and loaded up my old 48 Desoto.



Hear I am ready to roll out of OR,



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/HPIM0888.jpg)



Truck hauled well.  I used 4th gear, for any grades, 2000rpm at 55 mph.
 Mostly pulled at 7.5 lbs boost and about 850-900 on the pyro.  When
things leveled off I popped it into 5th.



Here's the truck at the first rest area I stopped at.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/HPIM0894.jpg)



Took me a little over 8 hours to get to Belingham WA, with a couple
major highway slow downs due to accidents...WA state and rain....who
knew they couldn't drive in that weather...(http://www.dieseltruckresource.com/dev/images/smilies/wink.gif)



Here's where I slept last night....Not the most comfortable sleep for a
guy my size, but good enough to save me another $75 for a hotel room.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/HPIM0909.jpg)



I arrived at the Canada/USA border at 8 am, got the US paper work taken
care of in a matter of minutes...the Canadians Customs...well I was
there for over 90 minutes and got the royal run around...(http://www.dieseltruckresource.com/dev/images/smilies/new1/madani.gif)



Here's one at the Canadian customs...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/HPIM0913.jpg)



And finally the Desoto is at it's new home.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/HPIM0918.jpg)



I was impressed at how well the truck did, the only thing that went
wrong was the clutch fan seized solid, so it's pulling a begeezes amount
 of air and making a heck of a noise at RPM's over 1500.  I have a new
clutch on the way.  So all in all a good trip and I'm very happy with
the way old RAE performed.(http://www.dieseltruckresource.com/dev/images/smilies/biggrin.gif)



I haven't fuel up, but think I used about the same amount of fuel, 15 gallons, and went 350 miles...so pulling it got 23 mpg!! Not
bad, a 750 mile trip on about 30 gallons of diesel!!!(http://www.moparnuts.com/forums/images/smilies/giggedy.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 08, 2010, 06:26:42 PM
does this mean I have to back 2 more years on the site? (http://www.moparfins.com/forum/smileys/smiley2.gif)(http://www.moparfins.com/forum/smileys/smiley2.gif)(http://www.moparfins.com/forum/smileys/smiley2.gif)
 
(http://www.moparfins.com/forum/smileys/smiley4.gif)(http://www.moparfins.com/forum/smileys/smiley4.gif) on the 48
 
I assume Rae ran like a swiss watch?   26 is great! 

 
 
 
 
 
 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 04, 2011, 07:38:44 PM
Wow been a while since I updated this thread. Done lots since then.



I ended up upgrading to the later 91.5-93 vacuum/power steering set-up.
 Got a complete set-up from Mark Nixon and was very happy with my
dealing with him.  Bought a reseal kit off e-bay and redid the entire
unit.  Came out great.  And works even better....I have 25" of vacuum at
 idle!!



The system when I got it....



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1967.jpg)



Then after a cleaning and reseal....



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1969.jpg)



Installed...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1972.jpg)



I had to modify the throttle bracket a bit to work with the new unit and
 brackets.  Had to cut off the bottom of the stock bracket, and then
drill a hole to mount on the new lower pump bracket. Turned out great
and was a very simple fix.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1974.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1977.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1973.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 04, 2011, 07:39:09 PM
Repainted my front door panels. Will eventually get the rear panels and
the other dash and trim pieces all painted in the gray and black theme.



Before...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1958.jpg)



After...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1957.jpg)



And installed...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1959.jpg)



While I had the door panels off I lubed everything and put on new door
plastic to help keep the dust/water and noise out a little.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 04, 2011, 07:39:34 PM
I've also since installed my gauges, Pyro, Boost and Tach.



Pyro and Boost on the dash....



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1940.jpg)



And the tach I used the old nub from the column shifter to mount it.  Almost looks like it belongs there. (http://www.moparnuts.com/forums/images/smilies/wink.png)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1939.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 04, 2011, 07:40:21 PM
April 04/11.....Just placed my order at Xtreme diesel performance for a brand spanking
new Fluid damper...they had a 10% off  sale going on, as well as one of
the best prices I could find...so out  the door $420!!  Can't wait!!(http://www.dieseltruckresource.com/dev/images/smilies/biggrin.gif)



I will definitely give an update of what I find...and feel.(http://www.dieseltruckresource.com/dev/images/smilies/wink.gif)



(http://www.xtremediesel.com/images/products/display/960311e.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 04, 2011, 07:46:39 PM
I just recently picked up a used HX35 turbo.  This is a nice step up
over the original H1C turbo I have on there now.  Will be dismantling it
 for a rebuild and then it will wait until I have the intercooler ready
to go before it gets installed.



Some pics...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4607.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4609.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4610.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 15, 2011, 03:12:17 PM
Well after a couple weeks of the exhaust side of the turbo fighting me tooth and nail...it did not want to separate!!  I heated, then soaked in PB Blaster , then more heat, then 50/50 ATF&Acetone mix, then more heat and more beating with hammers...on and on it went.  Well it finally let go the other day.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4641.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4640.jpg)

So now I can dis-assemble it and find out what rebuild kit I need to order. 


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 15, 2011, 03:14:08 PM
Well I got my New Sanden A/C compressor couple weeks ago, and finally got to cleaning up the used engine bracket.



Here they are waiting for install....



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4644.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4646.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4647.jpg)



Now one question on the engine bracket, do I need a gasket for the area
around the lower coolant connection...on the back of the bracket?



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4645.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 15, 2011, 03:15:04 PM
...my new Fluidamper!!!  What a beautiful piece!!!(http://www.dieseltruckresource.com/dev/images/smilies/biggrin.gif)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4643.jpg)



It's a fair amount bigger then the stock balancer..8 1/4" VS 9
3/4"...but should fit fine.  And a couple guys mentioned the need for a
1/8 spacer behind the clutch fan threads to clear the fan blades, well I
 measured the new damper and it measures out at 2 3/4" and I have 3 1/8"
 from the back of the stock damper to the fan blades.  Guess the Non-IC
fan hub sits out a little farther then the IC ones.  Might also be the
fact I'm running a 2nd Gen fan as well?



Just waiting on the rare earth magnets to arrive so I can attach them to
 the new fluidamper so I can keep my Isspro tach working.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 25, 2011, 06:04:01 PM
I finally decided to swap out my lower A/C and water outlet bracket.  I
am going to be finishing up my A/C retrofit soon and needed to get that
old C171 A/C compressor out of the way, and install my new Sanden A/C
compressor.



So I picked up a used lower bracket form a 96 12V motor.  Cleaned it all
 up and then  bought a rebuilt Sanden A/C compressor from these
guys.....



http://www.acpartshouse.com/ (http://www.acpartshouse.com/)



Here is the bracket and new compressor...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4644.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4645.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4646.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4647.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 25, 2011, 06:04:35 PM
Started by draining the fluid from the rad...Those drain valve location
sucks so I use an old rad hose to catch the coolant and re-direct it
into the pail.  Works like a hot ****!!



Then removed the belt and the Alternator, then the belt tensioner. Here's what the old set-up looked like.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4706.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4707.jpg)



Move the lower rad hose and unbolt he old C171 compressor.  There are 4
bolts on the bottom and one on the top.  Then wiggle and jiggle the old
compressor out.  Then remove the old water/ A/C bracket.  There are
three 13mm bolts around the water outlet, 2 short and one long, and
three 18mm bolts down low behind the old compressor location.



Here's the old bracket beside the new one.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4708.jpg)



Think it weighs 4 lbs less....(http://www.dieseltruckresource.com/dev/images/smilies/biggrin.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 25, 2011, 06:05:03 PM
Then install the new bracket.  I asked a bit ago about a gasket or
O-ring for the lower water outlet on the block but nobody seemed to know
 for sure.  Well it turns out to be a big O-ring.  I didn't have one so I
 put on a little RTV and bolted things back on.



The only thing I found was that one of the 3 bolts that go around the
water outlet is too long.  The old bracket had a 3/8 raised location for
 one of the bolts and the new bracket does not.  So I had to rummage
through my tins of misc bolts to find one that would work.



I didn't have the factory bolts to hold the compressor to the bracket,
so I bought four 4" x 5/16 grade 5 bolts, with washers.  Don't think the
 threads are standard thread since they were a little tight going in.
Make sire you put the bolts into the compressor before you try and
install it, or else you won't be able to get them in.



Here's the new bracket and A/C compressor installed....



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4709.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4710.jpg)



Not a bad job...other then the pouring rain today....(http://www.dieseltruckresource.com/dev/images/smilies/frown.gif)  Got everything back together and fired it up....no problems with belts length or anything.



So for all you Non-IC guys with bad compressors, here's your fix.
Though you will now need to get new lower hoses made up, but since I'm
doing the complete retrofit I will be making all my own anyways.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on April 25, 2011, 06:09:51 PM


What you don't work in the rain? (http://www.moparfins.com/forum/smileys/smiley36.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Leaburn Patey on April 25, 2011, 06:14:41 PM
Good work,Brian.
I am made of sugar,so no rain jobs for me.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on April 25, 2011, 07:20:52 PM
Sorry, I wasn't following the thread, would have suggested a paper gasket as minimum, or O-ring replacement, unless you used the old O-ring with RTV to help seal it. If you just used RTV, hopefully the pressure isn't too high and start a seeping leak, pressure and RTV don't go together very well (RTV has its pressure limits). Good job otherwise, and I will follow along better in the future. Anything else planned?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 26, 2011, 07:23:57 AM
Thanks guys! 

Well Dana...I did not disturb the old O-ring, just put a thin coat of RTV over the mating surfaces to help fill in any imperfection between the old O-ring and the new bracket.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on April 26, 2011, 01:44:07 PM
Hey Brian
I still have that 09 intercooler here.  It can be had pretty cheap too.  It's one of the skinny ones.  I just want to get it out of here, but it's not mine.  It has a whopping 500 miles on it.
 
Make a reasonable offer.  Weebee is coming down next month, I can send it back up there with him.  Lemme know if you want pics and dimensions
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on April 26, 2011, 02:13:34 PM
[/QUOTE]

Good job.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on May 02, 2011, 06:01:47 PM
Well the weather was crappy today...another fine day on the wet coast...(http://www.dieseltruckresource.com/dev/images/smilies/redface.gif)



So instead of yard work I decided to install my new Fluid damper.  Took
about an hour from start to finish.  Haven't driven it yet but seems
smoother at idle for sure.



I've had the damper for a couple weeks now and before I could install it
 I had to get some magnets for my Isspro magnetic tach set-up.  I
decided to use the cut outs on the new damper for the location of the
magnets.  I then ordered some rare earth magnets off e-bay.  I double
checked the polarity of the magnets that are on my original damper, so
they would be the same.



Here a pic of the damper with the new magnets....



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4732.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on May 02, 2011, 06:02:21 PM
Here's the before pics....



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4733.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4734.jpg)



And the size difference between the original and new damper....



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4736.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4735.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on May 02, 2011, 06:02:58 PM
I know a couple guys said they had to add a 1/8th spacer behind the fan
to clear the new, bigger damper.  Well I don't know why but I have about
 1/4" clearance with no other mods.



I have a 89 non-IC motor with stock fan hub.  I then have a new clutch
and a 2nd gen fan.  As you can see in the pics I have lots of room.



Here it is all done....



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4739.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4738.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4737.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on May 02, 2011, 06:03:32 PM
And then I had to figure out how I was going to re-mount the magnetic
pick-up for the tach.  I keep a bucket of misc small metal pieces and
random brackets and stuff I pick up and save for future projects and
what have you.  Anyway digging through my bucket I found an old bracket
from a sink I replaced.  It worked perfect for mounting the bracket.
Had tons of adjustment and everything works perfect.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4740.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4741.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on May 02, 2011, 06:10:21 PM


Did you seem y question about the intercooler?  It needs a home and the smuggler will be here in a few weeks.  I have to get it out of here.  It's almost perfect.  100 Bucks  It's from an 09
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on May 02, 2011, 06:12:11 PM


How's it feel with that balancer on it?  Any difference?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on May 02, 2011, 09:51:55 PM
Thanks for the offer on the Intercooler, but the 3rd Gen coolers are just too big for the 1st gen'ers.  I would need to cut off the fronts of my frame rails even with my rad support to make enough room for that 'cooler.  (http://www.moparfins.com/forum/smileys/smiley36.gif)

As for the wires, that's my Tach.  2 magnets 180* apart and an Isspro tach and magnetic  sensor kit.  Works great.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on May 03, 2011, 08:20:26 AM


Just trying to find it a home before the scrap man gets it
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on May 25, 2011, 11:18:24 AM
Well I picked up a spare/used IP off E-bay one night a few weeks ago.
Was surfing around late one evening and this IP popped up.  Description
said it had a lot of in/out shaft play and was for a core only.  With a
"Buy it Now" price of $100 I figured I couldn't loose.  Since even if it
 was toast I could probably salvage the piston head to use in my
original IP off the crewcab.



Well last night I decide to pull it apart to see what was going on.
From the sound, and movement of the main shaft I had a feel what was
going on.  Pulled the AFC off..no fuel after market fuel pin or
spring...and then pulled the head off.  Here's what I found.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4859.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4861.jpg)



The rest of the pump looks to be in great shape, minimal wear on the
case, rollers, cam plate etc.  So I think I will pick up a new set of
springs, a DGK-121 and have a spare IP ready to go just in case. (http://www.dieseltruckresource.com/dev/images/smilies/biggrin.gif)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Jason Goldsack on May 25, 2011, 11:25:57 AM
Major Score...!!!


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 23, 2011, 11:40:48 AM
Well yesterday we, my neighbor and I, went to pick up a 63 Impala that he just bought last week. The trip went great! Weather was super, maybe 20*C (70*F) at the hottest.  Trip up and down was about 420 miles, and I only burned about 17 Gallons of fuel!!  We left at 8:30am and got back around 7:45pm.

Anyone who's driven BC Hwys knows the big mountains you have to cross, over 4100 feet and lots of 8-11% grades.  The truck did super, sure glad I had the Pyro gauge though. I have a Post turbo set-up, and on a couple pulls I was 950-1000*, so about 1200-1300 at the manifold.  Figured out pretty quick if I dropped a gear and slowed down the temp would drop fast and hold at about 800* (1100 at manifold).  So most of the big pulls I did at about 35-40 MPH.

Here are a few pics....

Loading it up in Kamloops.....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5036.jpg)

Up and on, getting ready to go....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5039.jpg)

Stopped about 70 miles out to check chains....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5045.jpg)

And home....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5051.jpg)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Leaburn Patey on July 23, 2011, 02:34:43 PM
Good to see you reaping the rewards of your hard work and putting the truck to work.
(http://www.moparfins.com/forum/smileys/smiley4.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on July 23, 2011, 04:06:24 PM
You have me thinking for a while now.  I can get 2WD's pretty cheap.  I was thinking of getting one and restoring it so my wife and I can go on long trouble free crusis.
 
That truck looks absolutely awsome.  Good Job Brian (http://www.moparfins.com/forum/smileys/smiley4.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 23, 2011, 04:36:59 PM
Thanks Leaburn and Steve for the Kind comments. 

Once I get an Intercooler on there the temps will be more manageable.  I figured I'd use way more fuel I actually did.  Both my neighbor and myself were very surprised.  And my neighbor was very happy since he was paying for the trailer rental and fuel and food.  Cost him about $225 to go up and bring the car back....He's very happy about that.(http://www.moparfins.com/forum/smileys/smiley4.gif)

I say go for it Steve.  Very easy motors to work on, and dead nuts reliable once you catch up on the stuff that is regularly over looked in maintenance.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 20, 2011, 11:30:12 AM
I've been wanting to change/upgrade the pedal pads in the crewcab lately. I really like the original mopar
style ones with the stainless trim around them that came on a lot of the
 cars over the years.  Like these...



(http://www.darklair.com/images/new_pedal_pads.1.jpg)







Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 20, 2011, 11:31:16 AM
Well I finally found a pedal pad I liked for the clutch and brake.



Made by Mr. Gasket.  They say thy are approx 4" wide X 2.5" high...so very close to the original pedal size.



(http://i.ebayimg.com/00/$%28KGrHqJ,%21h4E2I79CUrlBNqz4Dej8Q%7E%7E0_1.JPG)



Will update with info and pics when I get them.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 20, 2011, 11:32:54 AM
Well I just got my Mr. Gasket pedal pads.  Don't think they are going to
 work though.  They have a concave curve to the back of the rubber pad,
so it does not sit tight against the metal pad of the pedal.  And then
it only has the 6 small metal tabs to hold it in place.  I installed one
 and after a couple dozen clutch throws it had wiggled itself loose.(http://images.ibsrv.net/ibsrv/res/src:www.dieseltruckresource.com/get/dev/images/smilies/frown.gif)



Oh well only out about $15.  Might try modifying them to work first before I chuck them in the junk bin.





Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 20, 2011, 11:33:24 AM
Well here's what I'm going to do with the pedal pads.  I'm using a
flapper disc to level out the pads.  Then I plan on using some screws
going down through the pad, between the raised pads, and into the metal
plate.  Then the chrome trim over to hide the screws.



Here are a couple pics so far...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5105.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5104.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5103.jpg)



Man what a dirty job removing all that rubber with the flapper disc.  I was blackened from head to toe....(http://images.ibsrv.net/ibsrv/res/src:www.dieseltruckresource.com/get/dev/images/smilies/laughing.gif)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 20, 2011, 11:33:46 AM
Well I finished them up this morning.  After my blackening from the
flapper disc and rubber, I figured there had to be a better way.
Finally decided that rubber cuts very easily with an exacto knife.  So I
 cut it down to almost the right height with the knife, then finished it
 up with a few hits of the flapper disc.



I ended up mounting the pads with 3 screws, some brass units I had in my
 misc screw container.  One on the top in the center and two in the
lower corners.  Then with the trim I had to shorten a couple of the tabs
 to clear the screws, and the main arm support.



Anyway here it is all done...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5111.jpg)



The throttle pedal is from a 71 Chrysler 300 I parted out.  The mounting
 is very similar to the original unit.  So it only required a slight
modification, a new nut and some locktite and it was done.



I think it turned out pretty good.  I only need to get the E-brake pad
done now.  Going to use the one from the 71 Chrysler 300 as well.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on August 20, 2011, 01:16:27 PM
Looks good to me, well done.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 20, 2011, 01:40:53 PM


Can't wait for you to get on the Desoto
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 20, 2011, 06:35:55 PM
Thanks Guys!!  I really like the look with the stainless trim...sure brightens up the pedals.

Steve...I too can't wait to get working on the Desoto this winter...big things to accomplish this winter.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 11, 2011, 07:59:33 PM
Well I've been searching for these for a while now.  I finally found a
set at a local wreckers.  These are the 16x6.5, 8 bolt steel rims used
on dodge vans and dodge ram trucks from 94-99-ish.  Most of the time
they were just the base, no charge rim, but I had seen a couple nice
sets and knew I had to have them.



So cleaned and painted the rims, found decent trim rings and good caps,
ordered the new lug nuts necessary to mount them on the 1/2 studs on the
 front, and then had my tires swapped over.



Now the back spacing is off a little between the stock rims and the new
ones.  The stock rim has about a 3 3/4" back spacing, and the newer 2nd
gen rims have a just shy of 4 1/4" back space.  I had ordered spacers to
 make up the difference but after installing them I don't really notice a
 big difference, and I actually think they look better set back in the
wheel well.



I've been painting the block letters on my tires with some white
vinyl/rubber dye...since I just love raised white letter tires.  Done
this in the past with very good success.



Anyway here are a couple pics.....



New rim with painted white letter tires..



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5270.jpg)



Now a full side view on rims and white letters...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5269.jpg)



And other side with just the black walls...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5271.jpg)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 20, 2011, 05:17:37 PM
But as of late I did manage to get a new front windshield rubber installed.  That was fun.  I had to carefully cut out the orignal glass...it was in great shape.  The clean up the little bit of rust under the front drip rail.  Then I had to drive it....with no windshield...about 20km to the glass shop that was going to re/re it. 
 
thrashingcows2011-11-02 00:38:17
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 20, 2011, 05:24:10 PM

I also just got a new (really good used) rear slider put in.  This truck has an odd ball back window...it's about 1 1/2" shorter then 90% of the other dodge trucks out there.  And there doesn't seem to be any rhyme or reason to when this smaller back window was used.  I've seen the smaller back window used form the mid 70's on up into the 90's...randomly. 

Anyway I scored this "new" one out of a 80 dodge ram in the wreckers....$35...Thank you very much!!! Needed to do a little work on one of the sliders since the plastic spacers on the bottom were gone...little back yard engineering and it's good to go again.  I then took it down and had the glass tinted.   This is an aftermarket unit, the original was leaking like a sieve since
 the joint was in the bottom drip rail...what engineering morron decided
 that was a good place to put a joint!!  Anyway the new one has it's
seams mid point on the outer left and right sides....much better
location!!

Here it is before....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1428.jpg)

And after....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5333.jpg)

thrashingcows2011-10-20 22:28:07
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 20, 2011, 05:35:06 PM


Lookin better and better Brian
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 20, 2011, 05:45:27 PM

Quote from: POLARACO

Lookin better and better Brian

Thanks Steve....Since it's my daily driver I have to do things a little at a time.  I'll get it restified eventually.  Wish I could paint like you though..

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 30, 2011, 12:22:01 PM
Well I decided to install the Cummins 3rd Gen 190* thermostat yesterday on my 89 Non-IC motor....things didn't quite go as planned.



I first removed the alternator and brackets, then went to remove the
thermostat housing...seems someone else tried a long time ago and
stripped off one of the bolt heads.  Thankfully it was the upper outside
 bolt and I was able to cut off the head and then pull the T-stat
housing and work with heat and penetrating fluid to get the bolt loose.




I then set to work cleaning up the T-stat housing.  I forgot to order
one of the big rubber/foam gaskets that seals the housing and lift
plate.  SO I carefully cleaned it up and re-used it.  When I went to
install the new T-stat I found that the outside diameter was too big.  I
 bought the thermostat off rockauto, after comparing dimensions and
stuff I thought it would be drop in affair....it was not. Seems the
original was 54mm and the new 3rd Gen unit was 58mm.  So I broke out the
 grinding wheel and took off 2mm all the way around to make it fit.



But during all this I wondered if a T-stat from a car/truck gasser motor
 would work.  I had a couple spares and tried one....dropped right in
and would have probably worked with no problems.  Anyone know why there
is a difference in gasser vs diesel T-stats??



Anyway I got the new T-stat into the housing, used some RTV silicon to
help seal the old gasket and bolted it up.  I managed to find a perfect
fit metric bolt in one of my "bucket-o-bolt" tins to replace the broken
original....was pretty happy about that.   Let it set up for a couple
hours and fired it up and took it for a drive.  Had a bit of an air
blockage for a while...she got pretty hot but eventually moved it out
and through.




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on October 30, 2011, 06:07:45 PM
Both control water, so unless the pressure is controlled through a heavier spring, no difference that I know of. I always, no matter what it is going into, drill a 1/16th inch hole into the face of thermostats so air bubbles get out faster. Doesn't hurt anything with the pressure or temperature itself, but it really helps with the initial overheating-then-the-thermostat-pops-open thing.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 30, 2011, 07:23:32 PM
Quote from: dana44
Both control water, so unless the pressure is controlled through a heavier spring, no difference that I know of. I always, no matter what it is going into, drill a 1/16th inch hole into the face of thermostats so air bubbles get out faster. Doesn't hurt anything with the pressure or temperature itself, but it really helps with the initial overheating-then-the-thermostat-pops-open thing.

 
The cummins 3rd gen T-stat I installed had two giggle pins in it, both 180* apart.  I installed it straight up and down.  The only other difference seemed to be that the cummins spec  unit was a lot heavier duty looking...function wise I can't see much difference.
 
 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on October 31, 2011, 06:55:34 AM
MY PT Cruiser had one of those, too, so I removed it. Needless to say, that 2.4 design is the best for burp cleaning, just top it off, put the cap on, pup a little extra above the hot line, never open the hood again. I have done it three different times now and not once did it overheat or have to be topped off later.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 01, 2011, 06:34:40 PM

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 01, 2011, 06:37:05 PM

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 01, 2011, 07:23:44 PM


Spray it with silicone so you don't take it off again
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 01, 2011, 08:33:48 PM
Quote from: POLARACO
Spray it with silicone so you don't take it off again


 
I have some light silicon spray from NAPA....this stuff...
 
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5355.jpg)
 
...Will it do the job?
 
 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 01, 2011, 08:34:48 PM
Here's a side by side of the old and new seal.....
 
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5354.jpg)
 
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5353.jpg)
 
 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on November 01, 2011, 10:21:06 PM
That spray will work, or even Armorall type spray (several brands), makes things slide together better (sticky rubber and paint), but your spray is just fine.
 
Does the square groove actually attach to a lip on the door?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 02, 2011, 08:14:35 AM
Quote from: dana44
That spray will work, or even Armorall type spray (several brands), makes things slide together better (sticky rubber and paint), but your spray is just fine.
 


 
Thanks for the info on the spray!  And yes the squared off side with the teeth and tin in it grabs onto the lip around the door opening in the cab.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on November 02, 2011, 09:27:17 AM
I wonder if the extra lip on top of the picture is large enough that it is keeping it either pushed out from the cab too far and making it tight. The other one doesn't have it, and it does look like it would pinch the round part a little bit thicker than it may be able to handle.
 
You can do a wet paper test to see where it is squishing tightest. Wet the paper lightly so there is a dry edge that would be along the edge of the rubber gasket, close the door, give the paper a tug and see where the paper tears off, a really tight pulloff would mean the tightest point, and if that extra piece sticking up may be worth cutting off. Comparison of the two indicates that lip is a lot less squish.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 02, 2011, 06:53:50 PM
The door seals bind up near the door latch and post assembly.  Really gets tight, tight, tight there.  Not sure if it will eventuall relax or not...hope so.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 02, 2011, 07:49:32 PM


could be the rubber doesn't have as much air in the compound than the original.  That's a closed cell ruvver extrusion
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 11, 2011, 06:59:35 PM
So I've been working on getting my 91.5-93 rad support ready for my install into the crewcab.  And I didn't want to spend the extra money on chasing down all the parts to swap over to an IC rad and hardware. 
So I decided to use what I have and do what "They" say shouldn't work.  I took my Non-IC rad and put it into my IC rad support. 
Here's how....
First I removed the lower rad support brackets...I cut the two welds on either side of each bracket, then used a punch to dimple the center of each spot weld and used my spot weld cutter to free them up.
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5375.jpg)
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5376.jpg)
Then tried to fit the rad into the support, it was tight on the lower corners and sides.
So I figured I needed to trim the lower dish shaped bracket and the little triangular protrusions on the upper supports. 
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5379.jpg)
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5380.jpg)
Did this and trial fitted again.....it fell into place....well it's tight but fits not too bad. 
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5383.jpg)
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5384.jpg)
Will have to fab up some custom brackets for holding it into place...but won't do that until it's in the truck and hooked up to the rad hoses.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 11, 2011, 07:36:36 PM


Got the Bus back today.  Runs good
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 11, 2011, 08:00:23 PM
Steve...That's the Non-IC rad from my truck.  Pulled it out so I could mock things up...and modify as needed.
 
So what was the damage on your injectors on the Bus....(http://www.moparfins.com/forum/smileys/smiley32.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 11, 2011, 08:18:35 PM


The total bill was around 1250.  They did my trans, AGAIN, so that was a $50 deductable.  So with the trans, 2 injectors installed and a tie rod end, I paid about 1325 total with tax
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 12, 2011, 07:40:32 AM
Right one...Glad you got them on the parts mark up....(http://www.moparfins.com/forum/smileys/smiley4.gif)   Nice that you have a good warranty on the tranny...paid for itself already.
 
 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 12, 2011, 08:52:03 PM
If you made it to the end I apologize for the long post...just need to vent a little on my brain fart antics, and other things I learned along the way.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on November 13, 2011, 08:05:59 AM
No problem with the long post, at least I only ended up with one question:
Is it possible that the head air bleed not being done in the beginning may have been the problem all along? That has to be one heck of a powerful water pump to cycle the fluids fast enough that a 1/16th inch hole allows too much bypass to prevent the engine from warming up.
 
In my 74 Barracuda 318 (built mildy) I had a 160degree thermostat with the 1/16th inch hole in it, and the only time I had a warming up problem was below freezing for eleven days in a row, at which time I cut a piece of cardboard and placed in front of the radiator. She never overheated in the summer.
 
Sounds like you need some version of the blinds that go over the front of big rig radiators to control the temp better, diesels do like to run a little warmer than gas engines.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 13, 2011, 10:58:56 AM
After cutting off the jiggle pins that were on my 190* T-stat it left two 1/8th holes.  It definetly let a lot of water through.  Enough that it would just get tepid in temperature...not hot.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 17, 2011, 04:23:02 PM
Well today was the day.  I finally decided to swap in my NOS 9mm Bosch injectors into my motor.  The truck has been progressively smoking more and more since I started driving it 18 months ago.  And with the help of the DTR I was hoping it was leaking injectors.

I have never done an injector swap..diesel or any other type of motor.  So I was researching, and trying to make sure I had everything I needed before I started.  I made the injector removal tool from the sticky last week...turned out great and worked even better!!

Here's my removal tool...into it for about $7....;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5428.jpg)

I had to remove all the lines...right from the injector pump to the injectors.  I tried doing it with them just pushed aside but it just wasn't working.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5425.jpg)

The 24mm nuts all came out with little to no problems. I had been soaking them in PB Blaster every night when I came home for the last week or so.  

Lines and nuts removed ready for pulling....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5427.jpg)

So on went the removal tool and they popped out with no problems.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5429.jpg)

The only problem I had was with clearance.  #1 injector I couldn't get the washers past the lifting hook so I had to figure out a way around that.  I finally decided on using a 7/8 box end wrench on the base, then putting the removal tool on top of that.  That gave me just enough clearance to get the injector out.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5433.jpg)

#4 injector was tight to get out too, but that was due to the top nut on the removal tool hitting the air horn.




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 17, 2011, 04:34:53 PM
Once I got all the injectors out I could see that they were in rough shape.  Every one had crud caked onto the tips, with some of the orifices plugged right up.  They were all never seized so I guess someone must have had them out, or swapped at some time.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5432.jpg)

I think #4 and #5 injectors were not sealed tight.  There was a lot of crud and oil in the bores.  The rest were all fairly clean.  So here are my new old stock injectors.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5436.jpg)

One didn't come in the original box and was missing the nut, so I had to re-use one of the originals....no biggie.  The only other thing I had to go get was the O-rings to seal the nut to the injector body.  I walked up to my parts store with one of the injectors and found that an o-ring, 5/8" ID x 3/4" OD x 1/8 dia were a darn near perfect fit.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5435.jpg)

Here they all are installed and ready to button it up.  I never seized all the bodies, and nuts when I re-installed them.  Torqued them up to 44ftlbs and called it done.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5438.jpg)

Here it is all buttoned up and ready to fire.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5441.jpg)

Took a lot of hand pumping on my piston lift pump to prime the lines, but #6 line just would not prime.  SO I hooked up all the other lines and started cranking.  Eventually it bleed out.  I then had to crank for probably 15-20 seconds before it finally started to catch and fired.




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 17, 2011, 04:40:09 PM
First thing I noticed after it fired up was the lack of smoke.  I had it plugged in the whole time I was working so it was warm.  I took it for a run around the block and I noticed no smoke.  Let it idle for a while and it still did not start smoking, before I would have had a big blue/white cloud forming.

I re-used the little copper washers on the return lines.  I forgot to mark and orient them before I removed them so I had to just throw them in any which way.  So I had a few leaks from those that required a little tightening here and there.  

I also had a few bubble coming up from around the nut on #1 injector.  I re-torqued that one to 55ftlbs and it seems to have sealed up.

So all in all I think it was a very good day.  Will drive it for a few days and post an update then.




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 17, 2011, 05:50:31 PM


What was the first thing I said on DTR? (http://www.moparfins.com/forum/smileys/smiley2.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 17, 2011, 06:13:16 PM

Quote from: POLARACO

What was the first thing I said on DTR? (http://www.moparfins.com/forum/smileys/smiley2.gif)

Yes yes...you were right.....(http://www.moparfins.com/forum/smileys/smiley4.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 17, 2011, 06:15:55 PM



Those injectors are 1/3 the size if mine.
POLARACO2011-11-17 23:16:48
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 18, 2011, 07:51:48 AM

Quote from: POLARACO


Those injectors are 1/3 the size if mine.

I had a late night shift last night and had to drive 60 miles rounder....what a difference!!  Truck is way smoother, not rattling the roof and everything else.  More power, and my EGT's have dropped about  100deg from where it used to run.  And no more smoke while driving and shifting.  I loved the truck before...but I love it even more now!!(http://www.moparfins.com/forum/smileys/smiley4.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on November 18, 2011, 08:08:32 AM
Always a good thing. Good to hear she is even better than before.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 18, 2011, 09:14:34 AM

Quote from: thrashingcows
Quote from: POLARACO


Those injectors are 1/3 the size if mine.

I had a late night shift last night and had to drive 60 miles rounder....what a difference!!  Truck is way smoother, not rattling the roof and everything else.  More power, and my EGT's have dropped about  100deg from where it used to run.  And no more smoke while driving and shifting.  I loved the truck before...but I love it even more now!!(http://www.moparfins.com/forum/smileys/smiley4.gif)
I got some stuff for you to try out. . . Next time the smuggler is down here, I'll send a bottle up
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 13, 2011, 04:30:23 PM
Well I did my grill upgrade over the weekend...to the 91.5-93 style grill.  But I'll start from the beginning.

I bought the grill pieces off e-bay many months ago for fairly cheap.  But a couple of them were busted up and cracked, and one grill insert was missing a chunk as well.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4862.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4867.jpg)

I decided that I would fix them myself.  So I happened to find a busted up grill at the wreckers that I was able to scavenge the missing piece from.  I then carefully trimmed the broken area and cut a piece to fit. Then cut, filed and sanded it until it was an almost perfect fit.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4934.jpg)

Then I cut small pieces of sheet metal as backing supports and glued them in place.  I like to use the "Marine Goop".  This stuff is almost impossible to break free once set-up...great stuff.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4938.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT4947.jpg)

After all was in place a cured I putty filled and sanded everything, then used a sandable primer and sanded some more.  Then a few coats of flat black and all was good.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5085.jpg)

I got the chrome grill through E-bay as well.  Just a couple bucks over a hundred shipped.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5087.jpg)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 13, 2011, 04:45:09 PM
So up to the weekend....I pulled everything off the front.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5468.jpg)



Then installed my new rad support.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5469.jpg)



And if you recall I modified my rad support just a little to fit my
Non-IC, down flow rad. I only needed to add a small "bushing" on the
bottom bolts below the rad, I used some 5/8" heater hose. Now I don't
have to worry about it hitting those bolts and rubbing through the lower
 tank.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5472.jpg)



I then had to make up some brackets to hold the rad in place.  I used
some box braces from a mid 90's chevy pick-up.  I liked theses because
the ends were threaded and ran a good sized bolt.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5475.jpg)



I then had to cut, bend and modify the pieces to get them where I wanted.  A little welding and grinding had them ready to go.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5477.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5481.jpg)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 13, 2011, 04:45:53 PM
The lower mounts I had to drill a new hole in the rad support, then make
 the brackets.  But I had to run an additional washer on the bracket so
that the lower mounting mount, that usually slips down over an already
threaded bolt, would not bend and twist out of the way....I figured this
 out the hard way.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5479.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5480.jpg)



And a couple more pics of the rad all installed and ready to go.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5484.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5483.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5486.jpg)



And the final pic...all done.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5492.jpg)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: 300rag on December 13, 2011, 05:48:04 PM
Nice transformation.(http://www.moparfins.com/forum/smileys/smiley4.gif)(http://www.moparfins.com/forum/smileys/smiley4.gif)





(http://i22.photobucket.com/albums/b313/300Rag/assorted/32c0e90e.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on December 13, 2011, 07:06:27 PM
Totally awesome. When I have broken plastic grilles and the likes, I take a soldering iron and will cut and bend as necessary, wire about as thick as a paper clip and bury them in the plastic. The wire heats up, melts into the plastic, then you can heat and smear the plastic over the wire. A little stinky, but you can then finish the plastic and not have a wire/metal show, but if it can't be seen to begin with, who cares, right? Good job, and a nice improvement. 


 
What's up with the leash on the front of  your truck? (http://www.moparfins.com/forum/smileys/smiley2.gif)
 
 
 
 
 
Just kidding, I know what it's for.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on December 13, 2011, 07:11:55 PM


Someday I am going to find me a Gen one.  Probably my last project
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 17, 2012, 07:25:42 PM
Well I've been looking for a Dana 70, with 354's, to replace the old 84 Gasser Dana 60 that is in the crewcab.  Priced out one..non LS from the local truck wrecking yard....$1600!!  I laughed in their face.  Then a couple parts guys who wanted $800-900 for one.  

Then I came across a guy parting a 1st gen on craigslist.  Called him and asked if he had a Dana 70 with 354's.  He said call back in 30 minutes and he'd let me know.  Turned out he had one from a 93, Dana 70, 354's AND limited slip!!  Asked him how much...expecting around $800...he says $400!!  I went to pick it up and I got the U-joint straps and bolts, and the lower shock plates.....Couldn't be happier!!

So here it is....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5741.jpg)

Going to pull replace all the seals....new synthetic fluid...and re/re the brakes.  Hope to have it in the truck before spring.  Speaking of springs I now need to order a new set of rear springs....since I saved so much on the axle. ;)




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on February 17, 2012, 10:07:03 PM
Outstanding job, and the right gears, limited slip to boot. Can't beat that.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 18, 2012, 08:34:59 AM
But man is that one heavy axle!  Took 3 of us to move it around.  But it should have no problem holding up the increased HP and Torque the motor should be making in the next little while.

The old D60 in there now was in serviceable shape when I pulled it apart.  But the axle shafts themselves were scaly rust, and the axle tubes were almost as bad.  Took a lot of cleaning to get things in OK shape.  But I question the integrity, and strength of the axle shafts since they are pretty pitted.  I figure it's only a matter of time before one of them decided to twist into two in a high torque situation.





Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on February 18, 2012, 09:02:23 AM
Naaa, those tubes are thicker than you think. Chances of twisting is near zero.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on February 18, 2012, 01:49:55 PM

Quote from: thrashingcows
But man is that one heavy axle!  Took 3 of us to move it around.  But it should have no problem holding up the increased HP and Torque the motor should be making in the next little while.

The old D60 in there now was in serviceable shape when I pulled it apart.  But the axle shafts themselves were scaly rust, and the axle tubes were almost as bad.  Took a lot of cleaning to get things in OK shape.  But I question the integrity, and strength of the axle shafts since they are pretty pitted.  I figure it's only a matter of time before one of them decided to twist into two in a high torque situation.




Are you planning on 0 to 60 in 1 second or something?  Or are you going to drive it like an old fart? (http://www.moparfins.com/forum/smileys/smiley2.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 18, 2012, 03:17:38 PM
Oh I drive like you are Steve......(http://www.moparfins.com/forum/smileys/smiley2.gif)

But I'd rather have a rear end that was designated for "Cummins" use, then a gas unit.  Just peace of mind for me.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on February 18, 2012, 07:02:47 PM
It was a Dana 60 rear end, right? I have seen less than 2 destroyed Dana 60 rear ends in my life. One was because the house it was towing caught fire, the other one kept going through axle bearings after it was used for logging. Well, not really logging, it was turned into an 8 ft by 10 ft stakebed to hold three cords of wood, and the guy would load it up once a day, drive it down the mountain, and to be able to cut a mile off the logging road, jump a canyon, well, kind of. More like a gentle piledrive off the ledge of about three feet into a rock riverbed, then crawl over the other side. Did it for seven months, made a lot of money, replaced three grilles, two radiators and ten repairs each, and each piece of glass in the truck at least once. Other than that, two wheel bearings was the only thing that went bad in it, so I would think they were strong enough, even if they aren't Cummins rated.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on February 19, 2012, 07:52:56 AM

Quote from: thrashingcows
Oh I drive like you are Steve......(http://www.moparfins.com/forum/smileys/smiley2.gif)

But I'd rather have a rear end that was designated for "Cummins" use, then a gas unit.  Just peace of mind for me.


Then you better change it then. . . (http://www.moparfins.com/forum/smileys/smiley2.gif)  Blew 2 injectors again yesterday  Grrrrrr
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 19, 2012, 09:53:25 AM
Well regardless of the potential strength of the Dana 60...it's getting changed. ;)

Well then I'll toss it up on the local craigslist and hopefully get a couple hundred for it.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on February 19, 2012, 10:21:12 AM
Should be able to get what you paid for the other one without a problem, make it an even cost swap.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Jason Goldsack on February 19, 2012, 10:47:01 AM
Makes me wish I kept my 1990 Cummins... :(




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 25, 2012, 06:23:11 PM
Well a fellow over on the Cummins forum I frequent made up some "FARGO" lettering for his crewcab conversion.  I had been thinking about doing the same thing so was thrilled when I saw what he did.  I contacted him, and through a fluke of circumstance he actually flew into my home town from Saskatchewan!!  We met up briefly and I bought a couple sets off him for my truck.

Anyway we finally had a few nice days so I go the decals on....whatcha think?

 
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5937.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5936.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on March 25, 2012, 08:13:19 PM
Hey, that's pretty cool, I like it.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 03, 2012, 09:53:49 PM
Little back story...



My truck box on old RAE is in nice rust free shape..just the inside is
beat.  The floor is as wavy as the ocean, and I have tow big holes cut
in the floor from the stacks that were in there.  As well as some cracks
 and damage to the inside sides of the box.  Outside the pass. side has
the typical crunch...from what I can't say but it's been mudded over and
 looks OK but still bothers me.



Anyway I have been keeping my eyes open for a new'er box, even looked at
 a couple locally.  One was no better then what was on my truck and the
guy wanted $400, He also had a nice mint one for $800....little too much
 for me.



Well one night a couple months ago I was cruising the west coast
craigslists and came across a listing for a 80-93 nice clean, straight
rust free box.  It was in Portland OR though.  Luckily I have a couple
friends who live just outside Portland.  A phone call, some texting with
 the def seller, some paypal-ing and my friends had the box at their
house.

























Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 03, 2012, 09:57:38 PM
Well last week I decided that Saturday I would get up early and drive down to Portland OR to pick up my "new to me" long box.  Crossed the Canada/US border at 5:45am and was in Portland by 12pm.  Visited for a few hours, then loaded up the box and got on my way.  Left Oregon at 3:30pm and crossed the border into Canada at 10pm.

I had thought through the whole loading the box in the back of my truck and eventually came up with this...

Cut up some 2x2's to fit in the bed stake pockets....then we would flip the box upside down and onto the stakes.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5969.jpg)

Then a couple of clamps on the inside.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5966.jpg)

And then 2 ratchet straps over the front, and back.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5958.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5957.jpg)

Truck performed well. Drove 750+ miles and burned about 27 Gallons of fuel...that's about 28 mpg!!  


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 03, 2012, 10:00:38 PM
And a couple more pics that I like...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5954.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT5962.jpg)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on April 04, 2012, 04:21:09 AM


Pretty clever
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: azblackhemi on April 04, 2012, 05:53:48 AM
Truck performed well. Drove 750+ miles and burned about 27 Gallons of fuel...that's about 28 mpg!!   [/QUOTE]
Sure is a funny looking camper shell you got there Brian. (http://www.moparfins.com/forum/smileys/smiley2.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on April 04, 2012, 07:50:36 AM
Hey, you can still get a sheet of plywood in between the wheel wells, and that is alway a plus. Good deal, didn't realize truck beds were quite that expensive. I know any of them are hard to find without the rest of the truck being attached to them, good find.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 04, 2012, 08:07:28 AM

Sure is a funny looking camper shell you got there Brian. (http://www.moparfins.com/forum/smileys/smiley2.gif)[/QUOTE]

Aint it the ultimate redneck canopy.....(http://www.moparfins.com/forum/smileys/smiley9.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on April 04, 2012, 09:32:14 AM

Quote from: azblackhemi
Sure is a funny looking camper shell you got there Brian. (http://www.moparfins.com/forum/smileys/smiley2.gif)
Let's see ya paint that sucker.  (http://www.moparfins.com/forum/smileys/smiley2.gif)  (http://www.moparfins.com/forum/smileys/smiley36.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 04, 2012, 10:19:31 AM

Quote from: POLARACO
Quote from: azblackhemi
Sure is a funny looking camper shell you got there Brian. (http://www.moparfins.com/forum/smileys/smiley2.gif)

Really only needs a burgundy stripe down the side and it will be a darn close match...for now.

Anyone have any thoughts on how to attach the trim to the new box?  The original box has those little pin/tabs to hook the molding clips onto, then the moldings snap onto the clips.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on April 04, 2012, 03:08:52 PM


 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 23, 2012, 09:12:44 PM
Well again done a few things and not updated....



I installed my new hood...old bathtub hood from pre 1980 dodge ram.
Sanded it down and primed it for now.  Will throw some color on it soon.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6499.jpg)



And you have to have the matching cowl cover too...



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6500.jpg)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 23, 2012, 09:15:06 PM
Also found that the hood latch system was totally different on the
pre-80 hoods...more like you tradition mopar car set-up.  So had to move
 the 90's style hood latch over and forward.  Hood is still a bit
loose...not tight against the fender stops.  Will have to cut down the
hood latch bar to bring it down a bit more.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6496.jpg)I

Then
 had to also dimple the hood a little to clear the latch, and run a
slightly shorter hood spring so the hood would close easier, and not pop
 up with so much force it nearly torn the latch from the rad support. 
Good thing I have saved most of the hood springs form all the mopars
I've parted out of over the years.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6498.jpg)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 23, 2012, 09:22:54 PM
Used two old bottle cap openers...the old metal ones you used to use as a kid.  Rounded end on one side, sharp point on the other.  These worked great to slowly peal the drip rails loose.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 23, 2012, 09:29:55 PM
And today I decided to finally strip off the original box and get it ready for the one I picked up in Oregon.
 

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 23, 2012, 09:32:26 PM

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on August 24, 2012, 06:35:55 AM
At least they did a pretty good job stiffenening it up for the fifth wheel attachments.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 24, 2012, 08:32:10 AM
Quote from: dana44
At least they did a pretty good job stiffenening it up for the fifth wheel attachments.


 
True, but they should have bolted the brackets to the frame in my opinion.  Would have saved me hours of grinding to smooth things out.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 24, 2012, 08:46:17 AM

Quote from: thrashingcows
Quote from: dana44
At least they did a pretty good job stiffenening it up for the fifth wheel attachments.


 
What else could you do with your free time?  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 24, 2012, 09:10:42 PM
Got the frame all cleaned up and painted.  Took a couple hours...ate through a few grinding disc.  Found out that they tend to explode if you get them too hot...(http://www.moparfins.com/forum/smileys/smiley36.gif).
 

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 24, 2012, 09:13:27 PM
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6534.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 24, 2012, 09:24:18 PM
There are rivets that were obviously ground down to remove ???  I am assuming it was the brackets I'm missing.  Tomorrow I will build a couple brackets, that will use the rivets and then I will plug weld the brackets to the existing rivets.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 24, 2012, 09:32:46 PM

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 25, 2012, 08:56:39 AM


Why not get a gallon of that rust converter from eastwood and spey the frame?  I did mine a couple of years ago and it's still holding up
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 25, 2012, 08:26:51 PM
Now to figure out how to mount the trim...???
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 03, 2012, 08:34:22 PM
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6361.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 03, 2012, 08:38:30 PM

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 03, 2012, 08:58:14 PM


Yer as bad as me
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: azblackhemi on September 04, 2012, 05:13:20 AM
Quote from: POLARACO
Yer as bad as me
Nobody's as bad as you Steve. (http://www.moparfins.com/forum/smileys/smiley2.gif)(http://www.moparfins.com/forum/smileys/smiley2.gif)(http://www.moparfins.com/forum/smileys/smiley2.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 04, 2012, 06:45:40 AM

Quote from: azblackhemi
Quote from: POLARACO
Yer as bad as me
Nobody's as bad as you Steve. (http://www.moparfins.com/forum/smileys/smiley2.gif)(http://www.moparfins.com/forum/smileys/smiley2.gif)(http://www.moparfins.com/forum/smileys/smiley2.gif)
(http://www.moparfins.com/forum/smileys/smiley17.gif)(http://www.moparfins.com/forum/smileys/smiley17.gif)(http://www.moparfins.com/forum/smileys/smiley17.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 04, 2012, 06:47:33 AM


We can tell where Brian eats
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 04, 2012, 07:02:58 AM
Quote from: POLARACO
We can tell where Brian eats



 
Guilty as charged....(http://www.moparfins.com/forum/smileys/smiley2.gif).....(http://www.moparfins.com/forum/smileys/smiley4.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 04, 2012, 07:03:16 AM
But be careful trying to get into the tight areas...I hit the roof with the metal nut on the underside of the wire wheel...but a few good gouges in the roof....(http://www.moparfins.com/forum/smileys/smiley7.gif)



 
 
thrashingcows2012-09-04 12:06:46
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 04, 2012, 01:27:08 PM
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6574.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 04, 2012, 01:30:34 PM

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 04, 2012, 01:37:50 PM

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 04, 2012, 01:44:27 PM
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6590.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on September 04, 2012, 05:10:32 PM
VDO has a pretty good reputation, I use their gauges all the time, so good call to change it, and good work on the mods.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 11, 2012, 09:06:38 PM

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 11, 2012, 09:10:55 PM
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6597.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 23, 2012, 07:22:25 PM
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6623_zpseef5f77a.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 23, 2012, 07:32:01 PM
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6628_zps27a70c96.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 23, 2012, 07:39:55 PM

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 23, 2012, 07:46:53 PM
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6634_zpsfc16e5a2.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 23, 2012, 07:49:10 PM
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6641_zps038d3823.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 23, 2012, 07:52:11 PM
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6643_zpsa72312be.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 23, 2012, 09:24:11 PM
What!  No Duct tape and crazy glue? (http://www.moparfins.com/forum/smileys/smiley2.gif)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 10, 2012, 04:58:46 PM
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6650.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 10, 2012, 05:35:44 PM
I have to say that the muffler did quiet it down a little...but still has a nice deep, throaty sound.  It took off a lot of the harshness the straight pipe produced.  Much less drone in the cab too.  And I have noticed no increase in my EGT's either.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on October 10, 2012, 06:10:12 PM
Sounds and looks like you have both been busy and have had a little free time on your hands. Great job.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 13, 2012, 08:44:17 PM
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6660.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 13, 2012, 08:47:49 PM
(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6667.jpg) thrashingcows2012-10-14 01:51:52
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 13, 2012, 08:54:45 PM

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 13, 2012, 10:49:02 PM


(http://www.moparfins.com/forum/smileys/smiley4.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on October 14, 2012, 07:04:48 AM
Looks good. Not bad at all for a first time, either.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 14, 2012, 07:14:59 AM
Thanks guys!!  I'm pretty happy with the way it turned out.   But wondered afterwards why I didn't paint the tops of the fenders?(http://www.moparfins.com/forum/smileys/smiley36.gif) 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on October 14, 2012, 10:55:23 AM
I wondered that, too, but didn't want to say anything. At least it is easy enough to go back and do it. No need to do everything at once, right? Snoopy said it best, "Why do now what you can put off until tomorrow."
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 12, 2012, 04:53:48 PM
Well for some time now I've had a driveline vibration.  But withing the last few weeks it was getting progressively worse.  Only really happened on the highway...all other speeds the truck was nice and smooth.
I had replaced all the U-joints, and had the 2 piece driveshaft balanced a couple years ago.  Only part that I didn't change at that time was the carrier bearing it looked almost new so I just went with it.  So I figured the vibration now must be coming from that older carrier bearing?
So last weekend I jack the truck up and go to remove the drive driveshafts and when I start to undo the straps on the U-joint on the axle I find one is loose.  And that there is a ton of slop in the U-joint!!  Turned out that the vibration was more then likely that single cup having all the needle bearing pounded into goo!!! 
So instead of just doing the carrier bearing, I now had to do a U-joint as well.  No biggie.  So I swap on the new carrier bearing...had to do a little back yard engineering to get the new one on...old one came off with the cutting wheel.  And install the new U-joint and put everything back in.
Now I figured I'd be riding in an Imperial with the new carrier bearing, and U-joint....WRONG!!  The vibration now is even worse then before!!  It now shakes from about 30mph on up to 50mph...then kind of lessens until 60mph and then shakes like a ba$tard on up to 85+mph.
I decided to try flipping the driveshaft, and U-joint 180*...this seemed to lessen the shake by a fraction, but still really bad.  And then tonight I was laying under the truck pushing, and pulling on the drive line and thought I could detect movement in the front section of the rear drive shaft.  So I replaced that U-joint as well.  Went for a drive and it's Still shaking horribly!!
Like I said truck was driving nice and smooth, other then at hwy speeds, when I pulled into the driveway...changed carrier bearing and rear most U-joint and now it shakes. 
So I would appreciate any, and all comments, thoughts, opinions on what this might be. 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 12, 2012, 05:13:53 PM
I have been doing some reading online and was wondering what the proper working angles would be for a 2 piece drive line in my crewcab? 
I'm running a NV4500, and the front section on the 2nd gen drive shaft, complete with 2nd gen carrier bearing.  The rear drive shaft has the front section from the 2nd gen drive shaft...yoke that slides onto the front shaft, and U-joint...then the rest is old gasser driveshaft back to the axle.
 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on December 12, 2012, 05:56:32 PM


 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 12, 2012, 06:25:24 PM
Yeah it's definetly the driveshafts that are making the vibration.  Pop it out of gear, on the hwy, and it still shakes.
 
Wondering if the new carrier bearing has changed the drive line angle....since the old one was sagging in the rubber?  Think I'm going to have to get under there and start measuring the angles.
 
 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on December 12, 2012, 07:45:36 PM
Is it a slip yoke trans end or bolted on? If yoke, it may be the rear yoke bushing that is causing the vibration. Grab the driveline at the trans yoke/u-joint and see if it moves around or is solid.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 12, 2012, 08:10:08 PM
Quote from: dana44
Is it a slip yoke trans end or bolted on? If yoke, it may be the rear yoke bushing that is causing the vibration. Grab the driveline at the trans yoke/u-joint and see if it moves around or is solid.


 
It is a slip yoke at the tranny and the carrier bearing...Now that you mention it there does seem to be some play in the yoke at the carrier bearing. Not a lot though....you can't see it, more feel it. I'd wager a guess at .010 to .020 in play.  Will check the tranny yoke as well.
 

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on December 12, 2012, 08:18:40 PM


This was a conversion to a diesel as I recall?  (http://www.moparfins.com/forum/smileys/smiley36.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 16, 2012, 06:57:40 PM
So now I have to see if I can get new yokes, and then a whole new 2 piece driveshaft set-up made.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on December 16, 2012, 07:38:40 PM
Last check you can do is the phase of the U joints end to end. On a flat surface, the driveline laid flat and the caps set flat should not have any twist between the two ends, including a slip yoke being off one or more notch driveline to driveline. Not sure if this was checked, a definite way to cause a vibration, including that yoke bushing in the tailshaft.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 16, 2012, 09:04:40 PM
But the worn slip yokes are probably causing all kinds of problems. Been pricing out "New" parts...won't waste my time with used items that may, or may not be any better then what I have. Anyway these parts are not cheap!! Just for slip yokes, and new midship stub...looking at close to $500. Then I need new drive shafts, balancing, etc...to have everything done right probably looking at over $1000 to $1500...or more...(http://www.moparnuts.com/forums/images/smilies/sad.gif) Will hit the local driveline shop and get a price from them too.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on December 17, 2012, 06:47:56 AM
You mean to tell me the driveline slip yoke bushing, which is about 3/16ths inch thick, the outside diameter of the yoke, and about three inches long, copper/lead/tin/steel babbit with an expansion gap running top to bottom is $500? Better check that again, I think that is the price of the whole tailshaft. As far as the angle on the driveline goes at the transmission, shim the rear crossmember to fix that problem. I can understand a little bit of an angle, where zero or less than 1* becomes a problem... think about a washer when it is on the spin cycle and it starts banging because it is off balance. When driving, a driveline with deflects as it moves, you actually want it to have a pressure (minor) at all times so a shift of weight/pressure doesn't act like sh*t hitting a spinning fanblade, parts could break, but if there is some pressure against it, those deflections don't happen. 

Double-check a tailshaft yoke bushing and tailshaft rear  seal.  I could see maybe $30-40 on the high side, but that price is equivalent to a torque wrench being $500, and I wouldn't pay that much for one, either.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 17, 2012, 07:23:56 AM
I'm  needing the actual slip yokes themsleves...not the just the tailshaft bushing...I'll have to do that as well.
 
When I push up/down, back,forth on the slip yoke coming out of the back of the tranny, and the slip yoke that slips onto the rear of the carrier bearing....they both have a fair amount of movement.  Which means that the splines are worn.  I assume the slip yokes are made of a lesser material, the the splined shaft inside the tranny, and behind the carier bearing? 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on December 17, 2012, 07:42:28 AM
Tail shaft itself along with the bearing cases are hardened, yes, slip yoke itself should be at least hardened given it is splined. 99 times out of 100 the yoke itself is fine, it is the outside bushing itself that is softer, thus the wear part, not the harder yoke, rarely the output tailshaft. The yoke moves so little in and out, and the splines move so little they rarely wear, needs to have a little play output shaft to yoke to keep from binding. Personally I would start with the bushing and rear seal, find out what occurs, it isn't one of those difficult parts to replace after the first check of the bushing first, lots of money saved if the bushing itself alleviates the vibration. Tailshaft bushing replacement is the more difficult part to replace and if you to figure the yoke is bad, it pulls out and the bushing work is still done for good, only thing wasted is about 45 minutes labor to remove the driveline if more needs replaced afterwards.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 17, 2012, 08:23:46 AM
That's good advice, thanks!!  I will replace the tailshaft bushing first, and see what happens.  I did the tailshaft bushing on the 727 in the wagon...shouldn't be much more difficult then that I hope.
 
What do you think then about the slop in the rear driveshaft slip yoke.  Where is slides onto the midship stub out the back of the carrier bearing?  I replaced the carrier bearing, and U-joints, and I still get a movement...a littel "clunk" "clunK' when I push on the yoke.
 
The midship splines have a blue "easy glide" coating on them, and it's not worn off...so probably no wear on that shaft or splines...but what about the slip yoke itself?
 
Maybe I'm worring too much abou the amount of movement though, you did say there would have to be some play or things would bind.  Wonder if I can find a spec for the amount of play there is supposed to be?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on December 17, 2012, 08:56:26 AM
Is it the housing or rubber itself that is flexing or the yoke itself? Shouldn't be at the yoke itself, might try to identify exactly what the clunk clunk itself is. The intermediate carrier bearing should be firm enough to essentially be an extension of the transmission end so the driveline itself is shorter, but enough deflection that engine and transmission movement to the intermediate carrier bearing flexes with it and not bind, but clunking isn't normal in my mind. This would cause a vibration as it tries to center itself and cause a harmonic vibration.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 17, 2012, 10:40:25 AM
I'm pretty sure it's the yoke itself that is moving.  When you push/pull on it it clunks against the slined midship stub.  You can see slight movement in the U-joint when the clunk is happening.
 
 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on December 17, 2012, 11:22:03 AM
By chance is there a grease fitting that can pack it with grease?
Some have one , fills the end and then out the spline area for overfill, which helps take up slack and make it gluide easily.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 17, 2012, 11:32:07 AM
Nope no grease fitting, but I have tried to pack it with grease manually.   But really wouldn't be a tough job to install a small grease nipple though...Hmmm.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on December 17, 2012, 11:33:44 AM
And there should be some kind of collar on the end of it to keep debris out and grease in, right? Kind of a 4X4 setup, but not sure what yours is.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 17, 2012, 01:02:38 PM
Actually it has a boot that slips over the end of the slip yoke.
 
And Thanks again Ed for all your help, and suggestions...(http://www.moparfins.com/forum/smileys/smiley4.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on December 17, 2012, 01:36:10 PM
Just a mechanical tech guy, trying to help a friend. That, and I hate to see throwing good money after bad, so I will keep watching for results.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on December 17, 2012, 06:21:47 PM
That's a mix of shafts.  Are you sure the sizes are correct?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 18, 2012, 05:30:59 PM
Well I've wondered since I got the truck if having two different weight drive shafts would cause some problems.  The front driveshaft is the corresponding, matched NV4500 unit...so it's heavy duty, with thick wall tubing, and HEAVY!  The rear driveshaft is the light, think wall gasser unit...with the heavy U-joint welded on.

You got it right Steve...it's a hodge podge of parts...but it was done, quick and ugly, with very little finesse or care about detail.  This has been one of my goals is to get everything back to the standards I expect.

 



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on December 18, 2012, 05:49:41 PM
I wonder if it's just a matter of balancing the shaft then.  I missed the modified part on the gas end. 
 
Is it always vibrating or does it start as you go faster.  The higher gears slow the shaft down so that's the key.  You know the drill.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on December 18, 2012, 07:22:59 PM
The shaft keeps increasing speed as you increase overall speed, it is everything in front of the output shaft that goes slower as they shift through the ratios. A heavy and light shaft should not cause a vibration. Either something is loose, twisted, bent, and as a matter of fact, as long as the two caps are dead flat to each other so there isn't a twist, and the tube itself runs true to include centering of the U joint itself, it will not vibrate, it is a balance thing. My old 68 Charger had a weightless, squared and true, untwisted driveline on it and at 138mph did not vibrate. The counterweights are added to speed up the process of building them, but squared takes longer but does not require weights (my mentor taught me this). At the same time Brian, have you done a good visual to see if some counter banance weight may have fallen off?  And from there a wheel? Some jacking up and blocking to allow the wheels to turn safely off the ground may help at this point. Heck, even a bent rim can do this. Driveline or wheels would still do this with the clutch pushed in because the driveline and wheels keep turning.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 19, 2012, 09:26:02 PM
I have yet to get the driveshafts out and test them for "trueness" on the shop floor.  As for weights...pretty sure there were none missing....but will doble check that too.  I'm 100% sure it has nothing to do with the rims and tires...since the truck was running nice and smooth just before I changed the carrier bearing, and U-joints.


 
From the reading I've been doing I'm almost certain that the vibration is from a worn slip yoke, or tailshaft bushing.  I will fill up the slip yoke on the midship shaft with grease and see if the vibration diminishes.  I will also order up a new tailshaft bushing and seal, and get that taken care of.
 
 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on December 20, 2012, 07:48:44 AM
I can't remember, but I thought I said that already.  LOL
 
The shaft has the weights on it, but was it balanced after the Mod? 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 25, 2012, 12:07:14 PM

Quote from: POLARACO
I can't remember, but I thought I said that already.  LOL
 

Yes before I started driving the truck I had the front shaft shortened slightly...since the yoke was basically snug against the tail shaft...and then I had all new U-joints installed.  I then had the two piece drive shaft balanced together.  So balance should be good....that's why I'm thinking its worn out parts.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 26, 2012, 02:25:57 PM
Then laster last evening we went for our annual family Christmas light drive around town, and there was definitely a reduction in the vibrations from the drive shaft.  So I think this is one of my problems.  SO guess I need to order up a new midship spline, and yoke.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 06, 2013, 07:34:32 AM
The tranny and carrier bearing mounts are just pieces of channel across the frame.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 06, 2013, 07:35:06 AM
Last night I decided to cut and paste my two systems. Use the new'er control stock, and the old wiring. Carefully made sure to match all the wires to the proper connections, and solderd them all together. Will try installing it this morning...hope for the best.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on January 06, 2013, 07:48:09 AM
Sounds like you are keeping busy. Sorry to hear about the wiper problem. I had my nylon bushing break on my Dakota about a month ago, over $8 for a dealer available new one, had to remove the hood valance and pull the wiper arms to get the new one installed, about an hour job, so I can only imagine the switch problem and time involved. Watch it turn out to be wiring elsewhere after all this work.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 06, 2013, 07:02:55 PM
Well here is a pic of the joining of the two harnesses....


(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6892.jpg)

I
 installed it, as I said earlier, and nothing worked.  But you could
hear the intermittent relay cycling, and power clicking into the
system.  SO I pulled the wiring out again and double checked my
connections....yup everything was exactly how it should be.  So after
that I re-install the wiring and decided to check the plug at the wiper
motor.  I was getting power to the plug, from different location
depending on if it was intermittent wipe or not.  And the washer fluid
pump was working...so I figured it had to be the wiper motor.

So
even though I had pulled the motor last night and it cycled fine, I
decided to use a spare motor I had.  Although this one had a different
wiring connector so i couldn't plug it in...but I had snagged  6" of
wiring with it so I was able to make a jump to the wiring in the truck. 
 And if your doing this don't forget the external ground.   So i hook
everything up, power it up and the motor works perfectly.  So this was
the problem. 

 So onto Rockauto to find an interchange
list...then out to the wreckers...grabbed an almost new one from a 91
Plymouth Voyager.  Came home and hooked it up first off with the jump
wires...and everything worked!!  SO out came the old motor...then swap
over the new motor onto the base plate from the truck, then re-install. 
 I now have wiper again!!


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 06, 2013, 07:31:49 PM
Beats driving in the rain with a squeegy and rain-x sucks
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Guests on January 06, 2013, 08:19:47 PM
YEAY!!!!!

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 04, 2013, 08:57:54 PM
Alright another step taken.  The shake from the drive line was getting
BAD!!  I pretty much figured my tailshaft bushing was toast...so I
ordered up all the parts and finally got to it over the weekend. 

Fairly
 straight forward...remove a bolt from either side of the tranny side
cover...where the PTO would go, and let drain.  Then remove drive
shaft(s) and tranny mount and cross member, and then find a 10mm 12Point
 socket to remove 8 bolts...use heat on each one to loosen blue
loctite.  Remove speedo gear assembly and it's ready to come part.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7010_zps311e0dac.jpg)

And rear section off....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7014_zps223d8bd0.jpg)

I
 had ordered a new 5th gear and nut from Quad4x4, since I was unsure of
what I might find.  I found everything in good shape, with the original
chrysler updated nut.  Everything appeared to be in fine shape so I left
 it alone for now.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 04, 2013, 09:08:00 PM
Now that the rear section of the tranny was off I could use a hack saw to cut through the old tailshaft bushing.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7016_zps14ce7507.jpg)

Once
 cut it just slips right out.  This thing was TOAST!!  You can see how
hot it had been getting, and there was very little material left on the
inside of the bushing.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7018_zps5d371874.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7019_zpse04b47ae.jpg)

I didn't snap any pics of the reassembly process....cold and raining and wasn't too thrilled about laying out in the weather. :(


 I put the new bushing in the freezer for a day...then brought the
housing in the house to get warm.  I then used a chunk of ABS pipe to
help drive the new bushing into the housing.  This was a chore
though...I should have warmed the housing up in the oven at 300 deg or
so...might have slipped in a little easier.  I ended up rolling the edge
 a bit, so I had to file and sand the outer section of the new bushing
to clean things up....not too bad though.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 04, 2013, 09:24:20 PM
I decided since it was all apart that I would play with my speedo.  My crew
 is a 84, but the donor was a 89.  I have a 96 NV4500 and a cable driven
 speedo.



Ever since I got the truck the speedo has spun too fast.  It has been
about 8-10 KM/H off.  I removed the speedo gear housing from the tranny,
 and as Mark Nixon has mentioned, it's your standard mopar speedo housing and gear
used from mid 60's on up into the 90's.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7008_zpsf29bb13e.jpg)



So I find a 27 tooth speedo gear inside.  I figure since I'm running
3.54's I should have a 35 tooth unit....nope wrong.  With the 35 tooth
gear I was now running 20 KM/h too slow.  So out it came again and I
swapped in a 32 tooth unit.  I'm now darn close...think my speedo is
about 1-2 KM/H slow....might have to get a 31 tooth speedo gear and try
that.  I have a good selection of speedo gears from parting out mopars
over the years...but I don't have a 31 tooth gear.  But these are
readily available.



I'm running stock 235/85/16 tires and rims...so this is pretty close to a stock set-up.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 04, 2013, 09:28:11 PM
And a couple pics of everything done and back in place....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7023_zpsf84b1f0b.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7026_zps2982a5ec.jpg)

The
 vibration is significantly lessened now...but something is still out of
 alignment, or balance. I'm going to replace my carrier bearing again
and see if maybe I got a bad unit right out of the box?  I bought a unit
 off E-bay so I can't return it for any warranty.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on February 05, 2013, 07:57:52 AM
Sounds like good progress. At least a majority of the vibration is gone, now it is some other little small detail. I guess carrier bearing first, driveline second.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on February 05, 2013, 10:25:06 AM



Critical parts I like to buy local.  That way I have someone I can throw it at. (http://www.moparfins.com/forum/smileys/smiley2.gif) (http://www.moparfins.com/forum/smileys/smiley2.gif) (http://www.moparfins.com/forum/smileys/smiley2.gif)
POLARACO2013-02-05 15:26:02
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 01, 2013, 06:34:18 PM

OK I finally made my decision...I`m going to convert the crewcab to a
4x4.  SO the hunt has been on for a donor.  I put a bunch of want ads on
 craigslist, and other on-line diesel forums and received a few
responses.  For some reason I got quite a few with cummins trucks with
3.07 diffs.  I wanted 3.54`s, but could live with 4.10`s.  I eventually
go a response from a fellow who had a complete truck sitting.  He said
the truck needed a couple grand worth of repairs so was going to let it
go cheap.



I thought this might be a good one.  So a couple weeks ago I went out to
 check it out.  turned out to be an original owner truck, 1993 Club Cab,
 Cummins, Auto 4x4, LE model...full load. Has a few issues, but he was
still using it for dump runs now and then.  I couldn`t pass it up!



I drove it home earlier this week....Here are a few pics.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7087_zpsd620917f.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7075_zpsfa9336eb.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7081_zps19df6978.jpg)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7091_zpsa9fc4297.jpg)


thrashingcows2013-03-01 23:36:04
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 01, 2013, 06:40:23 PM
The rear fuel tank strap had rusted out, and tank was hanging down...ratchet strapped helped here.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7074_zpsbf7430ff.jpg)

Brakes
 are soft...probably the RWAL valve on the back axle. But the thing
steered like a drunkin elephant on the drive home.  I later discovered
why...The couple on the steering box in toast.  I`m amazed it was still
steering it is so bad.Rebuild kit on order...;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7103_zps31ac27bf.jpg)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 01, 2013, 06:44:10 PM
The pass side door is stuck shut, and the door handle is seized.  So I
will have to wrestle the door panel off from the inside...should be
fun.  But it has a nice grey interior...going to swap everything over to the crewcab!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7111_zpscc28dc42.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7112_zps7ccc77b8.jpg)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 01, 2013, 06:47:10 PM
Motor only has 258K Kms on it...about 160K miles.  Runs nice and clean, no hazing or smoke.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7114_zps1467d4c3.jpg)

Going to swap motor over to the crewcab too when I do the 4x4 conversion.  Keep my Non-IC motor as my spare.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7129_zpse83649d3.jpg)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7127_zps77721946.jpg)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 01, 2013, 06:52:47 PM
I spent a few hours yesterday, and today, pressure washing the truck,
and then scrubbing it down.  Looks a lot better now.  Wife wants me to
drive this truck instead of the old miss matched crewcab...:D  I`m very
excited about swapping everything over to the crewcab.  I`m going to fix
 a few things on the 93 and then I might insure it and drive it a
little.  Will probably rebuild the front king pins and hubs as well as
service the diffs and everything else and get it all up to par before
the donating begins.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on March 01, 2013, 07:44:44 PM
Sounds like you have a pretty nice little project there. A shame he allowed things to go as bad as he did with the truck, amazing what people tend not to do and live with it, scary.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 01, 2013, 08:44:58 PM
Rear section of the frame has some pretty serious rust issues.  The rear spring hangers alone look like onions cut in half...if I hit them with a hammer they might come free from the frame....???

The truck might be too nice to part out...I don't know and that is subject to opinion.  But I don't think I could find another truck with everything this one has that I can use.  And the money is an issue as well....how much would I have to pay for another truck...more then this one I'm sure. 


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 01, 2013, 09:38:04 PM


I've been wondering about that
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 02, 2013, 01:54:40 PM
I did a service on the motor today...guy said it had been 3 years since the last one!!  The fuel filter took me over and hour to get off.  And it had a K&N filter in it...which looks like it's been in there for 10 years!  I have a nice new paper unit in there now.  Turbo is nice too....no slop or play what so ever...and by the look of the nuts and bolts it might have been replaced fairly recently.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 02, 2013, 08:07:18 PM


I'm surprised you waited so long
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 03, 2013, 09:52:49 AM
I will never run a K&N style filter ever again....after the piece of straw that went through my air filter on the wagon, then went down into my carb bowl vent, and eventually got lodged in the primary squirters.  If it can't stop a big piece of straw, then what else is it not stopping?

Another argument can be made....if these air cleaners are so great, then why do commercial trucks not run them?   Millions of miles behind a paper filter is all I need to know.

(http://www.moparfins.com/forum/smileys/smiley19.gif)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 03, 2013, 05:15:42 PM



I'll bet you had an open filter in that car.  Just shows how much volocity there is going on there
POLARACO2013-03-03 22:21:32
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 03, 2013, 05:50:42 PM
Nope was running the stock big 68 Style dual scoop air cleaner....Still don't trust oiled cloth air cleaners....if you want more flow...put on a bigger paper filter.

But back to my new truck....

I have been under the truck the last couple days....man is it rusty!!
I'm going to have to soak ever joint, nut and bolt with PB Blaster for
the next 6 months, then probably heat the heck out of ever fasteners
before I try to loosen things.  I don't even have bleeder screws on the
 front calipers anymore!!   Had to scrape, then poke all the grease
nipples to free them up...used half tube of grease or more filling
everything up.




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 27, 2013, 08:52:54 PM

Alright I figure I better update.  Been puttering on the donor 93,
trying to fix things so when I go to do the swap the parts will be good
to go.

I mentioned earlier that I did a service.  Here is a pic
of the nasty K&N I pulled out.  When do you think it was last
cleaned....:D

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7148_zps0e29735b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7148_zps0e29735b.jpg.html)

The
 pass door would not open. Door handle assemble would move, but the
latch wasn't moving. I had to crawl across the pass side and wrestle the
 inner door panel off so I could get access to inside of the door.  Once
 I got into it I found that the linkage was all good, no broken clips. 
So I pulled out the door handle...well there was my problem! 

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7155_zps931ac2be.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7155_zps931ac2be.jpg.html)

The
 mechanism for the button was rusted solid.  And it was stuck part way
between open and closed so the inner door handle wouldn't work either.  I
 dipped into my spare parts and had this all fixed and back together in
no time.  Door works great now!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 27, 2013, 08:59:45 PM

What else...well I had to rebuild the steering coupler.  Here's the original.  had about 180* slop in the steering wheel!!



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7103_zps31ac27bf.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7103_zps31ac27bf.jpg.html)



Took me about a week to get the shaft out of the truck.  The 12 point
3/8 bolts that hold the rag joint to the steering column, and steering
shaft were so rusty that I could not get any type of socket to grab.  I
eventually had to cut them all off.  Here is the shaft out, and all
apart...not looking too good.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7180_zpsc5ba4777.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7180_zpsc5ba4777.jpg.html)



I picked up a Dorman 425-253 steering coupler rebuild kit.  Cleaned everything and installed it.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7181_zps12f892ef.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7181_zps12f892ef.jpg.html)


Good thing I'm such a parts horder...I had to dip into my spare parts again for another good rag joint and fasteners. (http://www.dieseltruckresource.com/dev/images/smilies/wink.gif)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 27, 2013, 09:07:48 PM

I drained the cooling system, pulled the rad and cleaned it, and flushed
 the motor.  I then re-installed everything and ran a rad flush through
the system.  Made a visible difference in the amount of build up on the
cross flow cores.  But mad do these IC motor hold a lot of
coolant...over 4 gallons!!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 27, 2013, 09:14:27 PM

And most recently I've been working on the rear brakes on the Dana 70.  I
 had a visible brake fluid leak from the pass. side rear brake.  Thought
 I might get lucky and only have to replace a couple wheel cylinders. 
Well here's what greeted me when I got it all apart.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7194_zps52b2f055.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7194_zps52b2f055.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7195_zps5c255ec4.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7195_zps5c255ec4.jpg.html)

Well
 everything was toast! So I ordered up all new stuff. I did the 1.125"
wheel cylinder upgrade as well, and 3" shoes. But it was wearing 3"
shoes.

 Just finished the pass. side this evening.  Will start of the drivers side tomorrow.  Here's how things look now.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7229_zpsa9fcb8d3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7229_zpsa9fcb8d3.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 09, 2013, 08:24:19 PM

Alright time for an update on the crewcab.  I have been working on the
donor 93.  Insured it for a couple days and drove it around....drove
pretty well.  I fixed a bunch of things.  Got the cruise working. Turned
 out it was unplugged in behind the steering wheel, and one of the wires
 for the cruise got pinched when the steering wheel cover was screwed
on.  So fixed the wore, plugged it back in and viola!!  Cruise works!! 
The A/C was not working.  So I played around with a few things...jumped
the low pressure switch and nothing.  Did a bit of diagnosis and found
out that it was the WOT (Wide Open Throttle) relay.  Had a bit of a time
 finding the correct molded relay...but finally got the right one and
all works great now.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 09, 2013, 08:27:57 PM

Then it was front end rebuild time on the Donor 93.  Want everything to
be new for when I swap the diff into the crewcab..  I have been buying
all the parts needed to do a complete rebuild for a while now. I got
everything from tie rods, to king pins, to rotors and calipers.

Here's my pile of new junk.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7584_zps2af343a9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7584_zps2af343a9.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 09, 2013, 08:30:46 PM

So here are some before pics.  This front end, and pretty much every
drive train and suspension part on this truck is rusty and
crusty....almost would think this thing was a East coast rust belt
truck...but the body is in great shape!

Anyway crusty pics....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7518_zpsa74a7a15.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7518_zpsa74a7a15.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7523_zpscda318dc.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7523_zpscda318dc.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7525_zps3cb9fd60.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7525_zps3cb9fd60.jpg.html)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 09, 2013, 08:34:32 PM

I had been soaking all the nuts, bolts and fasteners I could find with
PB Blaster since I bought the truck back in March.  Gone through several
 cans so far.  But pretty much every thing I've had to put a wrench on
has required heat and more PB Blaster.

Got the front calipers off and found the rear pads, on both sides, in rough shape.....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7529_zpsba15cfb4.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7529_zpsba15cfb4.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7562_zpsc8247031.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7562_zpsc8247031.jpg.html)

I actually drove 2 days with front brakes in that condition...Dooohhh!!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 09, 2013, 08:38:04 PM

The the tear down started.  Again much heat and PB Blaster was used. 

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7531_zpscc2e9f59.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7531_zpscc2e9f59.jpg.html)

 Found the front splash shields were toast so had to order a new set.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7533_zpsfdde0365.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7533_zpsfdde0365.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7585_zps18387766.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7585_zps18387766.jpg.html)

I could go into crazy detail about pulling the front end apart...but instead I will just do a quick overview.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 09, 2013, 08:47:45 PM

Thank goodness I had headed someones advice and bought a 2lb brass hammer, and brass drifts....they have been a life saver!! 

The
 lower bearing plate on both sides was pretty much rusted in place.  I
removed the 4 bolts and had to beat on them mercilessly.  Had to beat
them 90 degrees so I could pound them out on the sides.  Here's what
they looked like.


(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7544_zps2372b453.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7544_zps2372b453.jpg.html)

Here you can see how crusty things were.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7546_zps7ec059d7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7546_zps7ec059d7.jpg.html)

Tie rods...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7576_zps120ed629.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7576_zps120ed629.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 09, 2013, 08:54:47 PM

Had a bit of a fight getting the king pin stub out.  Tried lots of heat
and the 3/4 drive socket with 7/8 hex head, and my big 3/4 drive
craftsman ratchet and a big 10ft bar.....and it would not move.  And I'm
 no light weight either...6'8" and 275lbs.

I finally remembered
someone posting up that they cut around the diameter of the stub.  So I
decided to give this a try.  Worked great!  After cutting it required
just a little extra heat, and a slight pull with the big bar and they
were free.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7550_zps43137d3e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7550_zps43137d3e.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7551_zps50cffaf4.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7551_zps50cffaf4.jpg.html)

Here
 you can see the condition of the upper king pin set-up...lots of rust
in those bearings.  Most of the grease in the front end looked like
chunky peanut butter.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7574_zpsa3e5748a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7574_zpsa3e5748a.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 09, 2013, 08:58:45 PM

The front axle shaft U-joints were another treat.  You couldn't even see the clips on the U-joint cups they were so rusted up.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7591_zpsece4e0f1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7591_zpsece4e0f1.jpg.html)

Again much heat and PB Blaster later I was able to get things apart.  You can see the U-joint was in rough shape to say the least. ;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7596_zps53f71a2f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7596_zps53f71a2f.jpg.html)

Got everything cleaned up and new Spicer U-joints...with grease nipples..installed.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7601_zpsb2e673ed.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7601_zpsb2e673ed.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 09, 2013, 09:05:13 PM

Then came the fun of removing the front gear carrier so I could replace
the front axle seals.  With some great advice I was able to get it out
with the help of a ratchet strap and a pieces of 2x2.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7608_zps625dce5d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7608_zps625dce5d.jpg.html)

Then
 I had to beat the old seals back into the housing.  Tried a few things
but nothing was working...so I had to get out my backyard engineering
cap.  Here's what I came up with.  A piece of 6ft 2x2 with a big washer
that was just slightly smaller in diameter then the inside of the axle
tube.  The a couple washers and a wood screw.  Worked like a charm!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7609_zps831a48e2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7609_zps831a48e2.jpg.html)

Getting
 the new seals in place was a lot of fun too... :(  Big socket and my
brass hammer.  Then slowly beat them into place.  And the nice thing
with the brass hammer is that if you miss...and you will...you won't
hurt anything.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 09, 2013, 09:08:10 PM

Can't tell you how many hours I spent cleaning and repainting all the
parts.  But I got everyting back together a couple weeks ago and all
seems good.

Few after pics..

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7623_zpseb99c793.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7623_zpseb99c793.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7631_zpsd62d8181.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7631_zpsd62d8181.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7634_zps18ddc0c0.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7634_zps18ddc0c0.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 09, 2013, 09:13:45 PM

And just last weekend I pulled the injection pump one evening.  Then
next day I tore it right down and resealed everything...and installed my
 M&H timing spacer too.  Will swap the 3200 spring out of the IP on
my Non-IC motor once it's all swapped out.  Then a few hours on the
third day and it was back in and running.

And that's about where
 I am now.  Just re/re'd the rear diff fluid the other night, and had to
 replace the long brake line since in wiggling it during getting the
diff cover off it sprang a pin hole leak.  Also cleaned out the axle
vent. 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 09, 2013, 09:17:15 PM

Today I had to replace the input shaft seals on the steering box on the
crewcab.  I replaced the leaking high pressure hose last week and then
the input shaft seal started leaking.  Cost $7 for the re-seal kit, and
about 2 hours to Re/Re everything.  I did it with the box still hooked
up...just removed the wheel and go at it.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on August 10, 2013, 07:50:19 AM
Outstanding project from the looks of it, and everything looks great. I can only imagine who owned the truck beforehand. One of those farm trucks that one drives so much for short trips and never off the farm, or barely off the farm to get fuel, thus little problems never really rear their ugly head because the wear/problems were so slow they just don't get identified. Thanks for sharing, and keep doing it, love the pictures before and after.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 10, 2013, 07:50:43 AM
(http://www.moparfins.com/forum/smileys/smiley27.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Snotty on August 10, 2013, 09:02:16 AM
Completed job looks great!  Was the rust from sitting, or is it regular east coast rust?  (We don't get stuff like that here except for sitting in a yard for many years exposed to rain.)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on August 10, 2013, 09:18:47 AM
Yeah, down here in San Diego area we get rust from the inside out from dust falling into the water drains then it rains (occasionally) and the humidity, collects in the silt and stays moist too long, rusting edges and inside spots you wouldn't think about rusting.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 10, 2013, 10:56:53 AM
I bought the truck off the original owner.  Local BC truck with 258450Km's on it.  He did drive it a lot up north...Alaska and the Yukon.  I just don't think regular maintenance was in his vocabulary...other then engine, tranny and diff fluid changes.  The truck still has the original shocks from 1993 in place....mostly rusted out though.  Think he cleaned the body regularly...but never pressure washed or cleaned the frame and suspension.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Snotty on August 11, 2013, 05:00:20 PM
Quote from: dana44
Yeah, down here in San Diego area we get rust from the inside out from dust falling into the water drains then it rains (occasionally) and the humidity, collects in the silt and stays moist too long, rusting edges and inside spots you wouldn't think about rusting.

Yes, I don't think too many people in the east experience ocean-caused surface rust.  The '79 Cordoba I had was owned by a Long Beach woman since new - I bought it in '97.  The underside and motor were great, but I had to replace the hood and many trim pieces.  The hood has two holes in it!!!  It reminded me of a buddy who was stationed at Fort Ord.  The rust built up on his Honda 750 like he was driving it through the tide every day.  I am glad we don't get that here either! (http://www.moparfins.com/forum/smileys/smiley31.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 11, 2013, 08:57:42 PM
Not this far inland.  But the prevailing winds blow out, so there is minimal damage.  
You remember that Pink 62 NYer I had?  That was a shore car.  Car was in pretty good shape
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on August 12, 2013, 05:35:33 AM
Yeah, but we don't have salt put on the roads out here.
 
Yeah, have to replace the front edge of my 68 Charger from sitting 500 yards from the beach for four years of storage. If it isn't salt breeze damage, it is windblown sand damage.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Snotty on August 12, 2013, 03:34:57 PM
Quote from: POLARACO

Only in pictures Brother.  I never saw it in person.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Snotty on August 12, 2013, 03:36:15 PM
Quote from: dana44
 it is windblown sand damage.

That is a Nevada problem!  Two years of living in Carson City did in my '70 Challenger windshield.  People told me it would be so and they were right!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 17, 2013, 08:43:52 PM
Well the tear down of the donor 93 is under way.  Yesterday I got the
running boards off....they fought me on every bolt and screw....they
were pretty corroded.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7719_zps9f195e9e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7719_zps9f195e9e.jpg.html)

And off...makes the truck look a lot higher.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7732_zps7cf45922.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7732_zps7cf45922.jpg.html)



 Then it was time to get the exhaust off and the drive shafts out. 
Again fought me on every bolt, nut and clamp. A lot of heat and PB
Balster once again.

Start...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7724_zpsb5632710.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7724_zpsb5632710.jpg.html)

Exhaust and driveshafts out....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7725_zps3a4c010b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7725_zps3a4c010b.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7726_zpsfdcec3e4.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7726_zpsfdcec3e4.jpg.html)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 17, 2013, 08:48:22 PM

Then I spent about 2 hours removing the 6 nuts from the studs that held the transfer case to the tranny.  Once again the rust and corrosion monster was in attendance. 

Ready to come out....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7727_zps207d720b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7727_zps207d720b.jpg.html)

And out....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7729_zps8a5060d5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7729_zps8a5060d5.jpg.html)

You
 can see the fluid in the adapter.  There was no seal on the
transmission tail shaft, only on the main shaft of the transfer case. So
 there was a lot of tranny fluid in there.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 17, 2013, 08:54:03 PM

And then today I spent most of the day working on removing all the
tranny cooler lines, linkage and getting the torque converter and bell
housing bolts out, and dropped the 4x4 shifter.  Again much heat and PB
Blaster to make all this happen.  Took me most of the day to get all
this done.  And once again I HATE Ma Mopar for mot putting a friggin
drain plug in the tranny pan!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7734_zps975730b2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7734_zps975730b2.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7735_zps788b3b08.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7735_zps788b3b08.jpg.html)

Tomorrow the tranny comes down and out. 


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on August 17, 2013, 09:10:32 PM
Don't feel too upset about the tranny pan drain bolt, almost nobody does it and haven't for decades, but at least you can get one for it later. Good job, lots of fun, and glad someone gets to do some things with their vehicles, I am mixing bags of concrete for deck post supports, which is a blast!
 
Been thinking about getting a Ram V10 and building that for the Nash. Can't afford the Viper V10, but bet I can get some good power out of the truck setup (tiny cam, amongst other things). Have to see how it goes, have a couple years before that gets done anyway.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 18, 2013, 07:30:57 AM
A V10 in the Nash...that would be cool!  Once the 4x4 conversion is done I will have a lot of "brownie points" to earn.  Which means I will be working on house renos too....;)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Snotty on August 19, 2013, 09:29:40 AM
Quote from: dana44
Don't feel too upset about the tranny pan drain bolt, almost nobody does it and haven't for decades, but at least you can get one for it later. 

Drain plugs in the pan are a bad idea, and one reason why so many manufacturers do not install them.  If they did, people would drain the transmission and re-fill without changing the filter - which is a further bad idea.  By forcing us/trans shops to remove the pan gives us/them no excuse for not changing the filter.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on August 19, 2013, 09:33:35 AM
Excellent point! I know changing the trans fluid has to be the messiest job in the world, but it makes sense.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 19, 2013, 02:34:02 PM
I agree, but a drain plug would be nice
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on August 19, 2013, 03:29:10 PM
That's why they give us aftermarket plug installation kits for the responsible pan drainers.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Snotty on August 20, 2013, 09:29:24 AM
Quote from: dana44
Excellent point! I know changing the trans fluid has to be the messiest job in the world, but it makes sense.

Amen!!  I really do not like doing it.  No matter how careful I still end up with arms that look like they are bleeding!!!  But, I still offered to service a friend's transmission just last week... as long as he promised to haul away the used fluid!  (http://www.moparfins.com/forum/smileys/smiley2.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Snotty on August 20, 2013, 09:30:00 AM
Quote from: dana44
That's why they give us aftermarket plug installation kits for the responsible pan drainers.

HA!!!  Sounds like a new 12-step group!!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 23, 2013, 05:04:06 PM
I have installed the B&M oil pan drain plug kit in all the 727's I've owned...since I discovered the little kit.  Makes servicing the tranny simple and a lot less messy.
(http://www.moparfins.com/forum/smileys/smiley2.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 05, 2013, 09:06:52 PM
Well have slowly been tearing the rest of the drive train out.  Got the tranny out about a week ago, and tonight got the motor out.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7891_zps1727bd69.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7891_zps1727bd69.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7893_zps3c40b63f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7893_zps3c40b63f.jpg.html)

Will continue tearing it apart.  Hope to get to pounding out rivets soon.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 05, 2013, 09:12:07 PM
The power steering bracket was loose on the frame, and the frame had been welded a coupe times....still cracked again.  Doesn't apear that the bracket is cracked...I hope.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7861_zpsa9c7490e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7861_zpsa9c7490e.jpg.html)

And the inner fender is rusted pretty badly right under the battery.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7862_zps14c6a447.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7862_zps14c6a447.jpg.html)

Haven't decided is I will try and repair this one, or just use the nice rust free one from the crewcab. 

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 05, 2013, 09:20:09 PM
Anyone tell me what these brackets are for?  The one in the red box.  There is one on each lower front of the inner fenders.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT75262_zpsa5b46d77.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT75262_zpsa5b46d77.jpg.html)


 I suspect it might have something to do with the factory snow plow set-ups?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on September 05, 2013, 09:25:17 PM
Looks great, and so much cleaner than all those old cars from our heyday wrenching. Battery acid, always a bad thing. Replace if better, paint with something that is battery acid resistant to help in the future.
 
I have been watching the last couple days, everyone must  be much busier than me. I come in about every 90 minutes due to the heat and sweat in my eyes to see if anyone is out there on the site and boy, been pretty quiet since the weekend. Glad to see someone else is doing stuff.
 
Had to replace the battery in the PT Cruiser. It was three and a half years old, which is about as long as any of the batteries have lasted in her since new, but that is the extent of cars, other than looking around and not buying a Dodge V10 truck for the Nash, that is!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on September 05, 2013, 09:26:32 PM
Sorry, missed the picture, and yes, I would agree, snow plow attachment. Probably a good location for adding a brush bar, too.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 06, 2013, 06:50:04 AM
Yeah I'm very busy with this conversion.  The weather has turned though...lots of rain now.  Was hoping for a long hot summer with it being dry into October.

Wow 3.5 years on a battery...guess the constant heat down there doesn't help them either.  I usually get between 5-7 years on my batteries.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on September 06, 2013, 07:08:24 AM
Yeah, for some reason this car goes through them this often, it is the fourth new battery since 2002. It has all the bells and whistles, mom never bought anything but the top of the line Mopars, so all the stuff runs contantly when shut off, security and all that, and has always been hard on batteries I guess. This is one reason I learned over the years to simply buy the least expensive new battery available, they go bad and warranty rarely makes up the difference when it comes to replacement. Wife's Mini does the same thing, once every 4 years or so.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Snotty on September 06, 2013, 08:21:09 AM
We've had good luck with batteries.  We bought Frances' Sebring in Feb. '09 and have not changed the battery.  I put the one in my Newp in '06.  It is getting weak but I am amazed at it's staying power!  I did put two in my Van between '99 and '07.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: 300rag on September 06, 2013, 08:35:25 AM
My 06 PT is still on the original battery, but I think it will be done when the cold weather hits this year.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on September 06, 2013, 09:42:15 AM
The original battery in my other PT Cruiser went 8 years and I changed it because winter was coming up and I had been getting slower crank starts, but it still started. The next battery lasted until about three months ago and has been out in the AZ heat since 2009.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Tom Dawson on September 10, 2013, 05:28:01 PM
I put in a Red top Optima in my 00 Neon when the battery crapped out in NC 2 years ago.
Tom

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 13, 2013, 08:58:16 PM

The tear down of the donor 93 continues.....Got most of the interior
stripped out.  My friend who's getting the cab will be so happy with how
 clean it is.  Just a little surface rust on the drivers side
floor...that's it!!  A little wire wheel work, and a couple coats of tremclad paint and that floors good for another 20 years.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8004_zps4026164f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8004_zps4026164f.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 13, 2013, 09:03:48 PM

I had hoped to use the nice grey bench seat in the crewcab.  Replacing
the red rear seat was the plan.  Well I wrestled the old one out,and
then installed the grey bench from the 93.  It turns out that a clubcab
bench seat is off set, or short, on the passenger side.  Here are some
pics to show the difference.

Drivers side....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7964_zps8709b018.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7964_zps8709b018.jpg.html)

Passenger side....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7963_zpsa39b2f17.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7963_zpsa39b2f17.jpg.html)

Also
 turns out the base of the grey bench is longer then the stock rear
bench. And the angle of the seat, and or the seat tracks, is greater
then the orignal as well. 

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7969_zps4ef0b025.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7969_zps4ef0b025.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7965_zpsc5057eee.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7965_zpsc5057eee.jpg.html)

So
 needless to say I didn't keep it in the truck.  Back in went the red
seat and I will just have to get a good grey seat cover for now until I
can have it re-upholstered.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 13, 2013, 09:12:07 PM

And I tore down the transfer case for it's conversion from 23 spline to
29 spline input shaft.  Never torn into a T-case before, so was a little
 worried.  But found a couple sources on-line with great write ups and
followed them. All went well.

Before..

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7803_zpsf970fbcf.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7803_zpsf970fbcf.jpg.html)

After with case all cleaned up...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8065_zpsd6f031f3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8065_zpsd6f031f3.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8063_zps96b694c7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8063_zps96b694c7.jpg.html)

Now I have to get the parts down to my machinest to get the work done.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 13, 2013, 09:18:29 PM

I had hoped to use the inner fenders, but the drivers side was too
rusty, and then once I got the pass. side out I found it was rusty too. 
 So I removed the mystery brackets and tossed them.  I will reveld those
 brackets onto my good inner fenders on the crewcab later.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7920_zpsf5d2270e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7920_zpsf5d2270e.jpg.html)


I also removed the shocks...all 4 were original units!!  These are the rear shocks.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7921_zpsf178822a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7921_zpsf178822a.jpg.html)

And
 this is basically how the truck sits now. Another day or two and it
should be ready to come off the frame and go to it's new home.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT7919_zpsa95fe7db.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT7919_zpsa95fe7db.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 13, 2013, 09:46:25 PM
Running Red tops in my truck.  Don't have to worry about acid spills or gasses from them.  Nothing will ever rot away that's for sure.  But Yellow Tops are better.
Polaraco has red tops, 7 years old now and still kicking strong.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on September 14, 2013, 05:53:22 AM
Glad to see and hear progress is moving along. Isn't rust a pain in the rear? Is the seat mounting so bad that shims wouldn't work, or what?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 14, 2013, 07:45:28 AM
Quote from: dana44
Glad to see and hear progress is moving along. Isn't rust a pain in the rear? Is the seat mounting so bad that shims wouldn't work, or what?

I'd have to oval out the holes in the floor by at least an inch toward the passenger side to get it even close to even.  And then there is the fact that the lower cushion on the grey bench is longer, so affords less leg room for people in the back.  And then there is the angle of the back of the bench seat too.  This seems to be greater as well which binds against the back of the cab.

So with all that going on I think I will just stick with the original seat.(http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on September 14, 2013, 07:52:58 AM
Yeah, that's a lot of little things. Seat covers it is.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 14, 2013, 11:40:22 AM
I'm confused on these cushions. (What a surprise)
Explain that again?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 14, 2013, 06:54:23 PM
Quote from: POLARACO
I'm confused on these cushions. (What a surprise)

The lower seat portion of the grey bench seat has a longer measurement towards the front of the vehicle,, when measured from the bench seat back. 

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 18, 2013, 11:11:16 AM
I see said the blind man
 
I like the red better anyway.  Has more class.  For a classy guy
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 07, 2013, 08:43:36 PM

Been busy busy finishing the tear down of the donor 93....and working on the T-case etc.  Pics and info to follow....

Got the rear diff out.  Which was no problem.  Getting the springs off...well that took me a lot longer.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8235_zps1a950dbd.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8235_zps1a950dbd.jpg.html)

3
 of the 4 bolts were seized to the inner spring bushing metal liners. 
So I Decided since I wasn't using the frame or brackets I would just cut
 the front of the eyes off. 

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8231_zps027e853b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8231_zps027e853b.jpg.html)


(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8228_zpsc12664be.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8228_zpsc12664be.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8229_zps8a654a15.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8229_zps8a654a15.jpg.html)

Next
 was getting the spring free...had to cook the rubber until it was soft
enough to slide off.  The rear spring mounts...which I knew were in
rough shape...turned out to be paper thing.  All the rust flaked off
when I was beating on the bolts trying to free them up. 

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8234_zpsd65bd0f9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8234_zpsd65bd0f9.jpg.html)

thrashingcows2013-10-08 01:48:10
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 07, 2013, 08:50:50 PM

And the cab just sitting there.  We moved it off the frame so I could finish tearing the frame down.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8236_zps6a7dff00.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8236_zps6a7dff00.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8237_zps0b589755.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8237_zps0b589755.jpg.html)

And a day or two later all that was left was a frame....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8263_zpsc7915a4e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8263_zpsc7915a4e.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 07, 2013, 08:55:09 PM

Then I had to get all the front 4wd brackets and cross members off.  So
removal of the rivets was at hand.  I ended up drilling out the heads of
 most of the rivets...then using a HD punch and a 3lb hammer to pound
them loose.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8264_zps216c82ee.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8264_zps216c82ee.jpg.html)

Only ones I used a grinder on were the main engine cross member...sionce they were easily accessed.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8265_zpsee6f46a8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8265_zpsee6f46a8.jpg.html)

And all the 4wd brackets removed.  Too me about 5-6 hours to get all the brackets off.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8270_zpsa5624c9b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8270_zpsa5624c9b.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 07, 2013, 09:01:32 PM

And the frame pretty much ready to be cut up and hauled away.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8273_zpsa2618948.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8273_zpsa2618948.jpg.html)

Now
 to cut up the frame I was not sure how I was going to do this...until
my neighbor, and friend, asked if I wanted to use his plasma cutter from
 his work....HELL YEAH I DO!!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8282_zpsf7839695.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8282_zpsf7839695.jpg.html)

15 minutes after getting the plasma cutter home this is all that is left of the frame.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8284_zps9ec2b742.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8284_zps9ec2b742.jpg.html)

I'm keeping the front frame horns as templates and reference for drilling and positioning the brackets into the crewcab frame.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8285_zps863cdddc.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8285_zps863cdddc.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 07, 2013, 09:04:21 PM

And that's about all she wrote for the donor 93...now it's sell a few
more parts to recoup some of my initial outlay....already recouped over
1/2 the purchase price for the donor 93!! 

I will start tearing into the crewcab in the next day or so.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 07, 2013, 09:15:06 PM

I've had the machine work done to the transfer case so I can run the
bigger 29 spline input shaft and bearing.  Dropped it off at my
machinist and he had it done in a couple hours....and charged me $60....:)

Before...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8062_zps1df6294e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8062_zps1df6294e.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8080_zps474d11a7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8080_zps474d11a7.jpg.html)

And after...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8146_zps548af011.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8146_zps548af011.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8147_zps498be6a3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8147_zps498be6a3.jpg.html)

And the difference in the bearings...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8077_zps4dd4751e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8077_zps4dd4751e.jpg.html)

I
 should have the T-case finished up tomorrow I hope.  Been working on it
 for a few weeks now...just a few minutes here and there, when I have
time between everything else.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on October 08, 2013, 05:30:59 AM
That's a whole lot of progress. When it came time to scrap my Dakota frame and body, I salvaged what I wanted and took a sawsall to everything else, threw it in the bed of the assembled Dakota and scrapped it out, came to roughly $325 after I saved the good parts. Scrap is going for good prices these days. Good job on the transfer case, big difference in the bearing size!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 08, 2013, 07:26:59 AM
I've already taken one load of scrap down...got $65 for that load.  The frame and a few other parts should net me a bit more.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 08, 2013, 08:04:14 AM
(http://www.moparfins.com/forum/smileys/smiley20.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 16, 2013, 09:34:54 PM
Quote from: thrashingcows
I've already taken one load of scrap down...got $65 for that load.  The frame and a few other parts should net me a bit more.

Got another $56 for the last scrap load. (http://www.moparfins.com/forum/smileys/smiley4.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 16, 2013, 09:37:20 PM

Well been working on a few things.  Pulled apart the rear springs...to
clean and drill for the wear tips to smooth out the ride a little.  Man
are these springs rusty!  And they had worn their tips into the upper
springs on most of them. 

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8304_zps1205c0dc.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8304_zps1205c0dc.jpg.html)

Spent
 about 3+ hours cleaning things...and still was not close to being
finished. So I said F-it and took the springs, and all the rear axle
pieces, and 4wd frame brackets to the sand blaster.  Should pick them up
 later this week.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8312_zps94e6917d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8312_zps94e6917d.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8287_zps16c97ba8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8287_zps16c97ba8.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8288_zpsdaedf2b8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8288_zpsdaedf2b8.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 16, 2013, 09:40:18 PM

Transfer case is all done.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8382_zps68d4abee.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8382_zps68d4abee.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8384_zps9f3cc6fd.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8384_zps9f3cc6fd.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 16, 2013, 09:49:15 PM

So today I official started tearing down the old crewcab.  Pulled the 2wd NV4500 today.

You can see the hole butchered in the floor. 

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8363_zps3f72fd2c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8363_zps3f72fd2c.jpg.html)

Think I will be finding a new tranny hump from a donor truck to make a complete removable hump.

Tranny out....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8370_zps1f4616ae.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8370_zps1f4616ae.jpg.html)

Came
 out pretty easy.  Removed the fan from the motor so I wouldn't crew up
the rad.  Good think I did I had to lower things a lot so the bottle top
 shift tower would clear the floor pan.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 16, 2013, 09:51:39 PM

The throw out bearing was in rough shape.  Think this why I got a growl, and scream, from it every once in a while.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8373_zps6b12a8c7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8373_zps6b12a8c7.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8374_zps77fd0f0a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8374_zps77fd0f0a.jpg.html)

I spin it and it's a little crunchy.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 16, 2013, 09:56:27 PM

When I bought the crewcab the guy claimed it had a new clutch assembly
installed.  I think he was right.  Clutch, pressure plate and flywheel
are in great shape and appear to have been replaced....even though I've
personally put about 30K miles on the truck so far.  Guess I'm easy on
the clutch. ;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8377_zpsa65a5868.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8377_zpsa65a5868.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8378_zpsf7e16709.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8378_zpsf7e16709.jpg.html)

So
 I'll be replacing the Throw out bearing, and installing a new pilot
shaft bushing.  The re-install everything.  Glad I waited to order a new
 clutch assembly...saved a few hundred.

Anyone have an clutch alignment tool they would part with...PM me if you do.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 16, 2013, 09:59:09 PM

Hope to have the front sheet metal off, and the motor out by Saturday. 
Then work a few days, and hope to start tearing the 2wd front suspension
 apart next week.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on October 17, 2013, 05:56:06 AM
Good deal. My '88 Dakota had one of those squealy throwout bearings, factory replaced, never had a problem with it after that, sold with 150K and original clutch. My '95 has 155K on its clutch and it is doing just fine. They must make clutches out of better materials or something, in the old days they used to last about 100K if you were good to them. For some reason I have never had a need to use a clutch alignment tool. Maybe I am just lucky or have a good alignment eye or something.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 17, 2013, 07:50:13 AM
Sure I can get one off E-bay or something.....You get one if you order a new clutch assembly.  You better with the cost of clutch assemblies for these cummins trucks...$500 is the cheapest, decent set-up!!

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 23, 2013, 05:55:08 PM

Updates...

Still waiting for the sandblast guy to get my stuff
done...he doesn't charge me much as long as I'm not in a hurry.  I have
plenty to do in the mean time.  But hope to get the stuff back this
week.

Got the motor out last Saturday.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8412_zps09889222.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8412_zps09889222.jpg.html)

Then had to work a few days.  Got the front sheet metal, and all the wiring off the front end yesterday.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8428_zpsc203999e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8428_zpsc203999e.jpg.html)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 23, 2013, 06:02:47 PM

The cowl area was in not bad shape.  Few small cracks starting, but not bad.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8437_zps04faebbe.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8437_zps04faebbe.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8434_zps284fa4d0.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8434_zps284fa4d0.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 23, 2013, 06:11:07 PM

Then today I got the rest of the suspension torn apart.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8438_zps3591ff87.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8438_zps3591ff87.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8442_zps7aa948ac.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8442_zps7aa948ac.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8441_zps9a06d90e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8441_zps9a06d90e.jpg.html)

So tomorrow I start drilling out rivets.  Hope to have all the cross members out by tomorrow evening.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 23, 2013, 06:47:36 PM
Refresh me .  Is this a RWD or a 4X?  Or are you converting it to a 4X?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: 300rag on October 24, 2013, 06:10:28 AM
So how is your neighbour liking you now??

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 24, 2013, 07:56:44 AM
Quote from: POLARACO
Refresh me .  Is this a RWD or a 4X?  Or are you converting it to a 4X?

Crewcab was a 2wd...converting it to a 4wd.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 24, 2013, 07:58:52 AM
Quote from: 300Rag
So how is your neighbor liking you now??

Both my neighbors, on either side of me, are car guys...so they don't care.  In fact they help out with a lot of things too.  The others in the neighborhood...well they have seen me out there working on my stuff all the time.  Sure they just shake their heads and wonder whats wrong with this guy....(http://www.moparfins.com/forum/smileys/smiley36.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on October 24, 2013, 08:05:58 AM
If they complain, explain it could be worse, you could have ten guys, ten trucks, and a keg on the front lawn, unless they prefer that.....
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 24, 2013, 09:55:01 PM

OK today I got the rivets all pounded out, and the cross members
removed.  Took me about 3 hours or so to get all the rivets out....about
 20 rivets.  Then I had to cut the inner brackets off the main center
cross member...would not come out other wise.


(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8443_zpsb27d920a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8443_zpsb27d920a.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8444_zps95a4f5cc.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8444_zps95a4f5cc.jpg.html)

And then a good pressure washing and scrubbing with so Simple Green.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8447_zpsc2e01e01.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8447_zpsc2e01e01.jpg.html)

Tomorrow
 I will get some paint on the frame rails...then start measuring and
drilling holes to mount the 4wd cross members and brackets.  Should have
 the front diff in by early next week.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 25, 2013, 10:00:35 AM
And now the fun starts
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 25, 2013, 11:52:00 AM
I just took my meds so I am chatty for a bit.


Gettin' old I guess. . . . Senile  LOL

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 25, 2013, 10:33:53 PM

OK today...or I guess tomorrow now...;) 

I worked on getting the
 frame brackets and cross member in.  Started by pulling out eh old
frame rails from the donor 93.  Started trying to figure out how I was
going to transfer the location of the holes from the donor frame over to
 the crewcab frame.  I started checking the location of the reference
holes in the in the frames.  The holes were close....but varied by up to
 3/8".  SO this was not going to work.  I finally decided I had to bolt
back together the donor frame with the cross members and take some hard
measurements.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8470_zps32406389.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8470_zps32406389.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8471_zpsdf5d0f69.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8471_zpsdf5d0f69.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8472_zps360100bc.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8472_zps360100bc.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8479_zpsa32f8e5c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8479_zpsa32f8e5c.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8493_zpsef079bfc.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8493_zpsef079bfc.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 25, 2013, 10:37:43 PM

Once I took a few dozen measurements I disassembled everything and
re-installed the forward cross member in the 84 frame.  But before I got
 too far into that I decided to mount, and drill the needed hole for the
 steering box brace.

Installed....and punched

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8502_zpscea7fe54.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8502_zpscea7fe54.jpg.html)

Drilled out to about 3/8"....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8504_zps58020bae.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8504_zps58020bae.jpg.html)

And then the final drilling was done with a step drill...worked like a charm!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8505_zps2450f1e8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8505_zps2450f1e8.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 25, 2013, 10:55:17 PM

Now the fun part.  Install the brackets and try and get all the
measurement s to line up...:(  I spent a couple hours running back and
for to the computer to check all the measurements.  I eventuallt got it
all blocked up and in position. 

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8514_zps353c7040.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8514_zps353c7040.jpg.html)


 I then noticed that the Driver side rear most upper hole in the bracket
 lined up almost perfectly with the center hole left by a rivet I
pounded out.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8516_zpsbff46120.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8516_zpsbff46120.jpg.html)

The passenger side was off just a little....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8517_zps17ea34c8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8517_zps17ea34c8.jpg.html)

I decided to install bolts and see where my measurements would fall.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8509_zps24a6ab93.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8509_zps24a6ab93.jpg.html)

So
 with the main center cross member bolted in using those two holes, All
my measurements are within a 1/16th to 1/8th...and some are dead on. 
Think I can live with those measurements.  So tomorrow I will double
check the measurements one last time, then start drilling.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 25, 2013, 11:06:41 PM
Better you than me.  I'd rather convert a car from gas to diesel
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 26, 2013, 06:46:06 AM
Quote from: POLARACO
I just took my meds so I am chatty for a bit.


Gettin' old I guess. . . . Senile  LOL

I was just not liking the look of the 2wd anymore.  The 1st Gen's just look so much better as a 4wd.  SO I decided I would do the conversion.  A bit of vanity I guess....(http://www.moparfins.com/forum/smileys/smiley9.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 26, 2013, 06:47:28 AM
Quote from: POLARACO
Better you than me.  I'd rather convert a car from gas to diesel

Yeah it a big job. Going from a gas to a diesel in a vehicle would be much easier. (http://www.moparfins.com/forum/smileys/smiley36.gif)

Now If I could get my sandblast guy to get my parts done I'd be much happier.  He's had them 2 weeks now and still not done....(http://www.moparfins.com/forum/smileys/smiley7.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 26, 2013, 08:35:26 AM

So I've been tearing apart my NV4500 the last couple nights.  Found a couple issues.



One was with the 5th gear that I ordered from Quad4x4.  I decided to see
 how it fit on the new 4wd main shaft but it would only go up to the
threads for the nut.  Not over and onto the splines...***!!  Turns out I
 got the right package, but the wrong part inside.  I have to say though
 Roy down at Quad4x4 has been more then helpful in fixing this issue,
and quickly!!



Second issue is when I got my 5th gear clutch and gear assembly off the
counter shaft, a couple teeth fell off the inside of the clutch!



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8530_zps30151b53.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8530_zps30151b53.jpg.html)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8532_zps2399f7ae.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8532_zps2399f7ae.jpg.html)



So looks like I will be needing a new clutch/cone assembly for 5th gear.
  I see there are aftermarket  units...anyone run one of these?  How do
they stand up?



I can get an NOS OEM unit from Quad4x4...but they are 4x's the price of
the aftermarket units!!  I personally think I will go with the
aftermarket unit.  Since I will never be turning up my motor to make
crazy HP or Torque.  And I drive, and shift very easy.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 26, 2013, 08:41:07 AM

Next problem I'm having is with removing the bearings.  Anyone who's done this in there shop/garage have any tricks to share?



I had to putt the cage and rollers off the counter shaft bearing so I could swing it up and out of the case.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8545_zpsd4be4d0b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8545_zpsd4be4d0b.jpg.html)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8554_zpsd78f3403.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8554_zpsd78f3403.jpg.html)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8556_zps49738004.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8556_zps49738004.jpg.html)



I don't care about the 2wd main shaft...it's toast anyway due to the 5th
 gear failing.  So I was just going to cut them off.  But the counter
shaft front bearing is sunk down within the gear...not sure how I'm
going to get that one out?



You can see it in the pic as I'm lifting the the cluster out.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 26, 2013, 01:08:05 PM
Ahhhh  It was good for another 1/2 a mil.  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 31, 2013, 05:21:17 PM



         Got all my rear leaf springs, and brackets etc back from the sand blaster.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8557_zps12c321f6.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8557_zps12c321f6.jpg.html)



One pf the front spring hanger brackets had a crack in it...V-'d it out
good...then welded it up.  Ground it down, and rat filed the opening.





(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8558_zps103d9cad.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8558_zps103d9cad.jpg.html)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8561_zps22a1e8bd.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8561_zps22a1e8bd.jpg.html)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8562_zps62c73581.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8562_zps62c73581.jpg.html)


















(http://www.dieseltruckresource.com/dev/images/statusicon/user_online.gif)



      (http://www.dieseltruckresource.com/dev/images/buttons/report.gif) (http://www.dieseltruckresource.com/dev/report.php?p=3209814)

       







         (http://www.dieseltruckresource.com/dev/images/buttons/edit.gif) (http://www.dieseltruckresource.com/dev/editpost.php?do=editpost&p=3209814)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 31, 2013, 05:21:43 PM

Been measuring, and measuring trying to get the front main cross member located properly.  Man what a pain!!



I had to pull out the front cross member to drilled out all the holes to
 get 1/2" bolts in where the rivets would be.  Then re-assembled.



And since the one hole was darn close I decided to use it.  But I found I
 needed just a little more wiggle room on the center cross member.
Turns out that it has a slight peek to it.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8626_zpsae00a316.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8626_zpsae00a316.jpg.html)



And once I leveled it out I also beveled the inside edge...since it buts
 up against the top radius where the frame rail is folded over.



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8627_zpsb3bd7187.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8627_zpsb3bd7187.jpg.html)



(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8628_zps5c7943ec.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8628_zps5c7943ec.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 31, 2013, 05:30:16 PM
Once I massaged the cross member I was able to get my measurements to within 1/16" to 1/8"...I can live with that.

Then it was carefully drill out the remaining holes.  Only had one go crooked on me...had to stop at 7/16" and rat file the rest of the way to 1/2".

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8630_zps489afb5c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8630_zps489afb5c.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8629_zpsf1274677.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8629_zpsf1274677.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8631_zps8230e2e2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8631_zps8230e2e2.jpg.html)

The nuts and bolts I used are just random pieces from my buckets of misc.  Will have to buy proper grade 8 nuts/bolts and washers.  Cross members have to come back out so I can paint the frame and brackets again.

Now I have to finish getting the rear most spring bracket positioned and drilled out.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 31, 2013, 05:38:18 PM
Rear top spring and brackets are down getting new bushing installed.  And due to the rust on my top springs, because of the void in the cast blocks between the top spring and the over load, I need to get solid pieces made up to replace the cast units.  

The spring shop recommended this or I might end up with a broken top spring at the corrosion area.  So I will take the old cast blocks down to my machinist and get him to make up a couple new pieces for me.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 31, 2013, 05:42:26 PM
Maybe you could look at some of those lift kits.  They may have what you need.  The bolt pattern would be the same.
Speaking of broken trucks. take a look at that Rog thread.  I broke my truck
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 31, 2013, 05:43:39 PM
I brought the NV4500 pieces down to my friends shop, and he removed all the bearing for me.  So finally got the rest of the tranny torn down.  Now just waiting on a few pieces and I can start re-assembly.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8604_zps066fdac7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8604_zps066fdac7.jpg.html)

Difference in the 2wd vs 4wd mainshafts....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8608_zps7c811ac7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8608_zps7c811ac7.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 31, 2013, 05:54:10 PM
Brian
Did your 2WD fronts come as taper bearings?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 01, 2013, 08:15:06 AM
Quote from: POLARACO
Brian

Yup the bearing in the tranny are all tapered...except the pocket bearings that go inside the gears..

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 01, 2013, 08:54:12 AM
I meant axles
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 01, 2013, 11:51:48 AM
Yup 2wd or 4wd they all come with tapered bearings.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 01, 2013, 12:34:36 PM

I've been going crazy trying to find the flange head nuts and bolts to secure the new brackets to the frame.



But Think I finally found a guy who really knows his stuff. I told him
what I was doing, and how I prefer to go over kill.  He told me that
Grade 8 bolts and nuts in this kind of application can actually be worse
 then using grade 5....since the grade 8 can crack and break due to
flex. So He's bringing me in matched nuts, bolts and washers that are
used in bridge building....so they will flex and still hold super
strong.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 03, 2013, 07:19:20 PM
After much advice from fellow board members...on other sites...

 I called and cancelled my ASTM nuts and bolts, and have ordered the 1/2"
 x 20 Grade 8 flange head bolts and Stover lock nuts from the McMaster-Carr
site...hope to have them by Wednesday at the latest.



I just was not feeling good about the Construction grade bolt, since they are technically a grade 5.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 03, 2013, 07:19:43 PM

I have had the clutch slave cylinder...what comes out of the
tranny...hanging down under the truck for a couple weeks now.  I noticed
 the other night a little fluid around the end.  Thought at first it
must be water...since it's been raining.  Gave it the quick tongue test
and it's brake fluid.



So I pulled the rod and grommet off and sure looks like it's leaking
around the cylinder.  Probably the front section of the bore that was
not traveled on was a bit rusty...then removing the tranny allowed the
piston to move up and over that rusty area....thus the leaking seal.



So can I reseal this myself?  Or should I just get a new one?  Also do I
 need one for a NV4500 or Getrag?  And I can replace just the leaking
slave cylinder assembly right?  They do come loose from the line?

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on November 03, 2013, 08:42:26 PM
If the slave cylinder is the same as the Dakota and PT Cruiser, plastic or cast body,  the plastic tube going to the top back of the slave cylinder should have a cotter pin or roll pin in the side that comes out, then there is a little rubber washer, the tube just pushes against it and doesn't leak. Rebuildable, probably, but you will notice there is no bleeder for them. They are a little bit of a pain to bleed, takes time for air to move up the tube and out of the slave itself, so you prefill it, install it, then let the last air make its way out on its own, or pump it about half an hour really slow and tap the plastic line to make the bubbles rise slowly (air in molasses fast air bubbles). The slow pumping moves the bubbles up and down, so you have to do it slowly,  too fast doesn't do any good, and it is time consuming. Other solution is to buy a fully sealed complete unit of both pieces pre-filled with fluid.
 
I kind of have to also agree with the grade 8 bolts. The strength is the tensile strength in its tighness to make them hold, so the stretch strength to clamp is more important than its ability to flex. Heck, I would even go so far as to put a tiny one or two second tack bead on the thread/nut as a guarantee it won't have to ever be checked from coming loose.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 04, 2013, 06:58:09 PM

Thanks for all the great advice, I appreciate it!!

And now for more good news....

Well
 I got an E-mail from McMaster - Carr today stating that because I live
in Canada they will not send me the nuts and bolts I want.(http://www.moparfins.com/forum/smileys/smiley7.gif)

Seems
that even though I was to have them shipped to my USA address, and then
bring them across the border myself...that this somehow violates all
kinds of international trade laws etc.  Since the final destination is
Canada.

They sent me a lot of info as to why they can not process
 my order, and I'm sure it's all legit...but come on Nuts and
Bolts??  If I was to purchase these items through a business within
Canada then they could accommodate my order.

So after a friggin week I still have no nuts or bolts to assemble my frame!!(http://www.moparfins.com/forum/smileys/smiley5.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 04, 2013, 08:44:46 PM
Why not just use the right sized bolts with heavy washers and locks?  I've don that before and never had any problems.


I agree with the Grade 5 though
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on November 04, 2013, 09:21:23 PM
I could see that with China, but Canada?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: 300rag on November 05, 2013, 05:51:38 AM
Have you tried these guys??  http://boltsupply.com/home.aspx (http://boltsupply.com/home.aspx)




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 05, 2013, 07:44:25 AM
Thanks for the link 300...I checked out there site and they do not have the fasteners I want.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 05, 2013, 10:35:32 AM
Well I hopefully have the right fasteners on there way!

I went across the border to my Local USA Napa.  The older woman who is an amazing parts person....was able to help me out.  She called her supplier...Fastenal in the US....and they had the stuff I needed in WA state.  Should be here tomorrow, Thursday at the latest.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 06, 2013, 03:53:42 PM

Nut and Bolt saga continues.....



So I open my E-mail this morning and there is a bill/receipt from
McMaster - Carr....WTF?  I look at it and it clearly states..."Canada Export - **DO NOT SHIP**"
  Then at the bottom there is a UPS tracking number.  So I check the
tracking...shipped the same day I received the E-mail stating that they
would not sell me the nuts and bolts, and was en-route to be delivered
to my US shipping address today...again WTF!!



I go back to the first E-mail I received from them, and called the guy
who sent it...no answer only voice mail.  Leave a long rambling message.
  Then I get on the phone to Visa...see if I can put a stop payment on
it...nope hasn't cleared yet.  Then I decided to go to the McMaster-Carr
 website and see if they have a customer service number.



I then call their Help line and explain everything that has been going
on.  And how I have already found bolts locally.  The guy said that they
 clearly F'd up and that they would refund me the cost of the nuts and
bolts.  I asked if they wanted them back...he told me to just keep them.



Now I needed to call Napa and tell them what has happened and that I now
 do not need the nuts and bolts they were bringing in for me.



So at the end of the day I finally have my nuts and bolts...at no cost
to me...and I can finally get the cross members and brackets in
tomorrow!!



What a friggin ordeal!!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on November 06, 2013, 07:19:32 PM
Well, under the circumstances, the hassle for the free bolts..... call it even. Go figure.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 06, 2013, 07:56:04 PM

Update in progress...

I made a couple templates and got the rear spring mount holes punched, and drilled. 

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8644_zps70cfed91.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8644_zps70cfed91.jpg.html)


 Bought a decent 1 3/4" hoke say to make the big hole in the frame.  I
used tons of cutting fluid, and then only cut in 10-15 second intervals
before adding more cutting fluid.  Took a good 5 minutes or so to, each
side, to cut through the frame, but my hole saw still looks almost new.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8647_zps03f7313b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8647_zps03f7313b.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 06, 2013, 07:59:38 PM

Got all new bushings installed in my springs.  Got them all smoothed out
 with the 60 grit flapper discs, and then painted.  Now I just need to
drill all the tips for the poly wear pads and reassemble.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8657_zps6c57c6d0.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8657_zps6c57c6d0.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 06, 2013, 08:07:51 PM

And since it wasn't raining today, and was a balmy 6*c (45*F) I spent
all day today with a heat gun and a can of paint working on the frame
rails.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8666_zps99085b09.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8666_zps99085b09.jpg.html)

And
 with my flange head nuts and bolts in hand I couldn't wait until
tomorrow to start assembling the frame. :D  Got the rear spring hangers
in first, Loctite 242'd and torqued.  Then it was slide the center cross
 member in place and then start on the front cross member.

First
thing I discovered was that things have to be assembled in a certain
pattern.  The three bolt that are behind the cross member have to go in
first.  I discovered that I needed to notch the cross member to clear
the head on the upper/forward bolt head.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8669_zps140acc50.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8669_zps140acc50.jpg.html)

Few minutes with the die grinder and I had lots of clearance.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8672_zps7ffbf787.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8672_zps7ffbf787.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8673_zps1907429f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8673_zps1907429f.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 06, 2013, 08:15:10 PM

Then it was the front spring brackets that need to go on next.  Slip it over the 3 bolts and then down under the frame rail.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8676_zpsd19cdf51.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8676_zpsd19cdf51.jpg.html)

To
 get it to suck up tight(er) under the frame and align with the holes
through the cross member and frame, I installed a nut and washer on the
lower bolt.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8679_zps04d4f426.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8679_zps04d4f426.jpg.html)

This
 got things "close" but it was still a lot of banging with the rubber
mallet, and prying with a tapered round pry bar to try and allign all
the pieces to get the bolts through.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8680_zpsb9d63c71.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8680_zpsb9d63c71.jpg.html)

Didn't install the nuts on the front cross member this evening though.  But I did do the main center cross member.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8681_zpsda0f4426.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8681_zpsda0f4426.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8682_zpscc266c7a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8682_zpscc266c7a.jpg.html)

It was after 9pm, and my back was killing me so I called it a night.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on November 07, 2013, 05:34:06 AM
Still looks good. Congrats on the progress.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 07, 2013, 03:08:42 PM
I see said the blind man
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 07, 2013, 09:01:31 PM
So today it rained like crazy...thankfully around 1-2pm it started to let up.  I raced out and got the rest of the bolts tightened up.  And I then decided to hang my Parabolic front springs.

 (http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8684_zps4c586fc8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8684_zps4c586fc8.jpg.html)  

Finally starting to look like a 4wd!!


Rolled the front diff into the garage so I could clean up, prime and pain the spring mount areas.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8701_zps9439f971.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8701_zps9439f971.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8700_zps6a9a4643.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8700_zps6a9a4643.jpg.html)

And since it's only about 6*C (45*F) and humid as heck...it's a little hard to paint.  I have started heating the parts with the heat gun, then spray them...then more heat from the gun.  Seems to be working OK.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8693_zpsb1a2aae5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8693_zpsb1a2aae5.jpg.html)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 07, 2013, 09:10:03 PM

The other day I also picked up my parcel from Silicone Intakes...my
boots, T-clamps and spacer for my Power stroke IC install.  These pieces
 should allow me to use my stock tubes....I hope!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8656_zps540ec0ec.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8656_zps540ec0ec.jpg.html)

Very
 nice pieces...and their site was great with all the measurements for
every little part. And the prices, and shipping were good too...I'd
recommend them!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on November 08, 2013, 05:48:53 AM
Yeah, the heat gun thing works well. Beats the heck out of picking up a piece and leaving fingerprints in it the next day. Good progress.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 08, 2013, 07:44:35 AM
Quote from: dana44
Yeah, the heat gun thing works well. Beats the heck out of picking up a piece and leaving fingerprints in it the next day. Good progress.

I'd been using old hair driers for a while.  Then decided that a heat gun would probably work better.(http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on November 08, 2013, 08:58:55 AM
Got one about 25 years ago and it has come in handy from time to time. They work well when torquing the heads on turbo engines. If you torque the heads and then warm them up through the ports, turns out head bolts torqued to 90lb-ft cold have around 55lb-ft of torque once they are warmed up, which explains why head gaskets blow on turbo engines so often.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 08, 2013, 03:25:34 PM
Quote from: dana44
Got one about 25 years ago and it has come in handy from time to time. They work well when torquing the heads on turbo engines. If you torque the heads and then warm them up through the ports, turns out head bolts torqued to 90lb-ft cold have around 55lb-ft of torque once they are warmed up, which explains why head gaskets blow on turbo engines so often.

Wow....never thought of how the bolts would stretch, and loosen the torque, when warmed like that.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 08, 2013, 04:22:36 PM
Also, put a drop of oil on the threads before torquing.  They'll stay tighter, longer
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on November 08, 2013, 09:15:09 PM
Dissimilar metals and heating things up make them expand and shrink differently, kind of like heating an old bolt up to get it loose, right?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 08, 2013, 09:44:23 PM
Spent over half my day running around trying to find more nuts and bots....Sheesh....[dummy]  I was looking for bolts to secure the steering box plate to the frame.  They were 9/16 x 20 x 1.5" and grade 8.  I needed 3 of them....I finally found them at Raider/Hansen.  But I needed to go with 2" long ones since I was installing the inner steering box brace.

All installed...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8706_zpscc644422.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8706_zpscc644422.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8705_zps6f2b7ee3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8705_zps6f2b7ee3.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 08, 2013, 09:47:43 PM
Then the most satisfying addition to the project so far...Front diff is under the truck!!  Halfway there to becoming a 4wd!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8710_zpsab9d7278.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8710_zpsab9d7278.jpg.html)

Quite the gasser look to it.....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8712_zps35de147c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8712_zps35de147c.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 09, 2013, 02:41:14 PM
I believe there is an aftermarket steering box support for that year.  The 2nd gen, the box was moved inside the frame which had more problems.  They crack the frames and brackets at the bolt point.  I'll see if I can find one for you
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 09, 2013, 02:59:40 PM
Shot my mouth off.  I can't find any now.   I'll poke around
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 09, 2013, 05:06:56 PM


(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8705_zps6f2b7ee3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8705_zps6f2b7ee3.jpg.html)

This is the only style of brace I've seen...after market Mopar unit usually seen on Ramchargers, but also found on 2wd and 4wd pick ups.  Only other ones I've seen are after market ones that require boxing the frame, etc.

  I never plan on running big tires, or major off roading. So likely hood of the frame cracking is pretty slim I hope.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 09, 2013, 05:48:06 PM
The ones I know of don't require boxing.  It was a bolt in and attached to the bottom of the box itself.  It went on the bottom of the pitman shaft with a bearing and the pitman went over it.  The rest bolted to where the sway bar bolted to the frame.
You could put larger washers in the inside of the frame.  That brace looks like a band aid
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 09, 2013, 06:29:59 PM
2nd Gens have a frame brace like that...but I've never seen, or heard of one for the 1st gens.  I've even seen this type of steering box brace being made for muscle car mopars too.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 09, 2013, 07:38:49 PM
Yes  That is correct.  I remember seeing one that extended out to the box on the first gens and bolted up.  It was made by a maker of the ones you described.  2nd and 3rd gen boxes are inboard the frame.  They still used the Saginaw box.  It prevented the leverage the steering put on the box.  When you look at it, there is a fair amount of leverage on the box at that point.  I'm thinking it's been discontinued, or the people that made them went out of biz.


POLARACO2013-11-10 00:43:13
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 12, 2013, 07:05:05 PM
Hmmm...thanks for the info Steve.  I've never come across any reference to these.  I will do some digging, and asking and see what I can find.  But for now this brace is better then nothing.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 12, 2013, 08:36:21 PM
Agreed.  The actual box bracket is where the bracing is needed.
I have a thought.  How about welding a tab on the bottom of the bracket to the frame and adding a bolt through the frame.  Maybe one on top would work.  It will prevent the bracket from flexing
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 15, 2013, 10:09:04 PM
Been working on getting the rear springs all back together.

I thought my neighbors drill press had a slow slow setting...but ti would only go down to 800rpm.  I drilled 3/8 pilot holes at that speed first using some areo space drill bits I picked up at a swap meet...worked really well.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8729_zps8ff409d3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8729_zps8ff409d3.jpg.html)

Once the small holes were drilled it was on to the big 7/16 bit.  Couldn't find any decent cobalt bits...so went with some bits designed for Stainless Steel.  Worked pretty good.  Slow speeds and lots of cutting fluid.  But since the drill press wasn't slow enough I had to do all the big holes with the hand drill.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8767_zps58985b57.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8767_zps58985b57.jpg.html)

That sucked...legs and back hurt a lot. :(

 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 15, 2013, 10:17:29 PM
I had bought some wear tip pads on-line...thought they would do the job.  Went to install them and they just wouldn't sit nice and snug.  Even though they said they were for 7/16" hole.  So I went down to my spring shop and bought some of the ones they use...nice and long...and work in 7/16 - 1/2" holes.

These are the ones I originally bought....

(http://i.ebayimg.com/t/Leaf-Spring-End-Tip-Wear-Pad-Anti-Squeak-Insert-/00/s/OTYxWDEzNjA=/z/X6MAAOxyx-BSbmC6/$T2eC16Z,!zYFIcnrdt3gBSbmC5q,LQ~~60_57.JPG)

And the here are the ones I got from the spring shop...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8768_zpsf9f653a5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8768_zpsf9f653a5.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8769_zps730e4cf8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8769_zps730e4cf8.jpg.html)

Got everything drilled...new wear tips installed, and then bolted them back together.  I re-used the old Zinc liners since they were in decent shape.  Once I had the spring packs together I had to take them back down to the spring shop to get the pack clamp brackets (???) installed.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8772_zpsd8e6096f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8772_zpsd8e6096f.jpg.html)

Just need to paint he brackets and they are ready to go in.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 15, 2013, 10:24:30 PM
Since the springs are now done I decided to attack the last thing to remove on the NV4500.  It is the input shaft bearing retainer race.  I thought I would just slowly cut through with the dremel in two places and then tap it out.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8774_zps2e2dcf81.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8774_zps2e2dcf81.jpg.html)

Seemed like a good idea in theory....but I guess with all my banging and hammering to try and free up the old race and get it out of the way I ended up cracking the bearing retainer...:(

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8775_zps7c8059c2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8775_zps7c8059c2.jpg.html)

Cracked at the oil feed hole.  I'm assuming that the bearing retainer is toast now?  Anyone have any thoughts on this?  

I don't want to half a$$ things...if it has the potential to fail and cause me grief I'd just as soon replace it.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 15, 2013, 10:29:32 PM
Just waiting on my machinist to finish making up new top blocks for the spring packs.  The cast block that sits on top of the spring pack and then the over load spring(s) sit on.  Since my top spring was so rusty under that cast block, with it's big voids that trap moisture, my spring shop recommended new solid blocks be made up.

They said the slightly longer solid blocks would help spread the load over a larger area, and help keep that rusted out top springs from cracking.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 16, 2013, 09:23:18 AM
 
I was searching out new bearing retainers
last night...The price on them is very reasonable.  I was also looking
at the outer surface where the throw out bearing rides....looks pretty
worn, and I can feel slight depressions.  SO I think this crack is a
good thing, as those depressions could be why the old throw out bearing
would hang up from time to time.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 17, 2013, 05:43:23 PM

Been sick the last couple days...:(  So only doing a little puttering on
 the truck.  I decided to start welding up some of the cowl area cracks,
 since the wind and rain had stopped for a little while.  I still need
to finish them off, and then make a couple reinforcement plates as well.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8776_zps8bb1a971.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8776_zps8bb1a971.jpg.html)

I
 also trimmed down the tranny tunnel so it would cover up the ugly hole
hacked in the floor.  Will make it a removable panel just in case I ever
 need to get at the top of the tranny. ;)

This is what I'll be covering....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8363_zps3f72fd2c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8363_zps3f72fd2c.jpg.html)

And the new panel...before trimming....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8777_zps49bde836.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8777_zps49bde836.jpg.html)

And after...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8780_zps8e1e2dfc.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8780_zps8e1e2dfc.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 17, 2013, 05:49:42 PM

I also went to install my sway bar.  I had used Rockauto to get the part
 number for the Moog sway bar bushings....K7302 for a 1 1/16" bar.  I
never measured mine and when I slipped the bushing over my bar...nope
does not fit!!  So I measure my bar and I have a 1.18" or 1 3/16" bar. 
So I have to order up some K7328 bushing instead.  

This is the
first time I can recall that the Rockauto site has led me astray, or
maybe I have a bigger bar for some reason???  Their site does not make
mention of this bushing period...so I don't know?


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 23, 2013, 06:23:53 PM
So my machinist called and said he finally got my plates done.  Did a really nice job on them.  Little bit longer then the original, and all flat, so should distribute the load better over the slightly compromised top spring.  All this was suggested by the guys at the spring shop I use.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8784_zpsf73b67a2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8784_zpsf73b67a2.jpg.html)

Then Got the 2wd Dana 60, and all springs, hangers etc out of the truck on Friday.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8794_zpsa0f04932.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8794_zpsa0f04932.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 23, 2013, 06:28:35 PM
Today I installed the Re/Re'd springs from the donor 93, and got the Dana 70 in place and bolted up.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8798_zpsc081769e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8798_zpsc081769e.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8803_zps6196f4af.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8803_zps6196f4af.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8804_zpsa029311d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8804_zpsa029311d.jpg.html)

Had some fun with one of my shocks.  The factory installed the bushings in the wrong ends...top for bottom and vica versa.:(  Took me, and my friend and neighbor, about 2 hours to carefully remove the bushing and swap them around.

And all done and sitting pretty....Damn it's going to sit high!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8801_zpsf74989ed.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8801_zpsf74989ed.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: 300rag on November 23, 2013, 06:51:03 PM
Looks like it's coming along nicely. You must be able to see the light at the end of the tunnel.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on November 23, 2013, 07:07:21 PM
What is that, a six inch lift kit?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 24, 2013, 12:46:21 PM
Don't you have some cold Canadian air yet?
I know you sent a bunch of it down here
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 29, 2013, 08:08:07 PM
What is that, a six inch lift kit?[/QUOTE]

Nope that is all factory springs and lift blocks.  That is how high the truck will sit when done...give or take and inch or so.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 29, 2013, 08:09:09 PM
Quote from: 300Rag
Looks like it's coming along nicely. You must be able to see the light at the end of the tunnel.

Yeah there is light now.  The hardest parts are almost all done.  Maybe another month or so to finish it up?

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 29, 2013, 08:10:52 PM
Quote from: POLARACO
Don't you have some cold Canadian air yet?

It's been pretty mild here on the "Left Coast".  Plus I like the cold...so I'm out there regardless...and not that I have a choice either. 

I remember you out there working on the 62 in very inclement weather.(http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 29, 2013, 08:10:58 PM
Been working on the NV4500 4wd conversion the last couple days.  Got the counter shaft in and end play set to .002".  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8811_zps3247caa3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8811_zps3247caa3.jpg.html)

Then it was start assembling the new fully splined 4wd mainshaft.

Start...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8812_zpsace682c2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8812_zpsace682c2.jpg.html)

All done and ready to roll into the case....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8822_zpsd355f4a2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8822_zpsd355f4a2.jpg.html)

And the tranny starting to look like a real functioning unit....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8823_zps74e47b3b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8823_zps74e47b3b.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 29, 2013, 08:16:27 PM
Picked up my new front bearing retainer today.  Not a bad piece...but it did require a little grinding on the oiling passage.

Not sure if you can see it in the pic, but the casting was almost level where it ran across the oiling hole.  Once the bearing race was installed I doubt much oil would have gotten through.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8813_zps553e5c2c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8813_zps553e5c2c.jpg.html)

A minute or so with the die grinder and a stone had things opened up....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8814_zpsc393905c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8814_zpsc393905c.jpg.html)

Make sure you guys check these things when buying "new" parts....(http://www.moparfins.com/forum/smileys/smiley2.gif)


So tomorrow I should have the tranny pretty much all back together....Wohoooo!



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on November 30, 2013, 07:22:26 AM
Good progress, and love the pictures. I tend to open all new oil pumps and give them a little tweaking to improve the flow, too.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 03, 2013, 08:12:14 PM
Almost got the tranny finished tonight...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8829_zpsae40af21.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8829_zpsae40af21.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8828_zpsc367d561.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8828_zpsc367d561.jpg.html)


........then I noticed that the shift rail rod for 5th gear is worn badly...:(  So now I have to wait on one last part before I can finally finish the tranny.  Little cheesed off I never noticed the wear on that part before now.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8830_zpsdf76f0a5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8830_zpsdf76f0a5.jpg.html)

Oh well I have a million other things I can work on in the mean time.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 05, 2013, 08:34:37 PM
So since I'm waiting for my shift rod to arrive ...I've been working on some other things.

Yesterday I got the front swaybar installed.  Had to drill the holes on the underside of the frame to mount the bushing.  Thank goodness I had bought a short 90* air drill some time back. :)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8836_zpscc196058.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8836_zpscc196058.jpg.html)

And I straightened the spot welded pinch seam on the tranny tunnel.  Previous owner(s) cut and bent it to all heck.  So I straightened it, and then trimmed off the excess...and there was a lot!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8417resize_zps6b7823f2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8417resize_zps6b7823f2.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8835_zpsf1239fc3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8835_zpsf1239fc3.jpg.html)

And I started to make up the over plates to reinforce the cowl crack areas...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8833_zpsd84529c0.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8833_zpsd84529c0.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 05, 2013, 08:38:02 PM
Today I decided i would work on the rad support.  I had to re-install the lower mounts for the IC radiator.  Since I had removed them to run the old Non-IC rad.  Glad I saved all those brackets I removed....;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8843_zps5f3a17e2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8843_zps5f3a17e2.jpg.html)


(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8844_zpsd6d2a9b2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8844_zpsd6d2a9b2.jpg.html)


(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8850_zpsadb9fa2c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8850_zpsadb9fa2c.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 05, 2013, 08:43:13 PM
Then I thought I may as well get started working on my PowerStroke IC install.  

I used the old front bracket for the Dodge IC I had removed before.  I cleaned them up and trimmed them down just a hair on the one side.  Then moved them all the way out on either side.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8847_zps0f23026c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8847_zps0f23026c.jpg.html)

I then spent the next 2 hours trying to find the original bushings that mount on the bottom of the OEM IC and go into these brackets...never did find them.

So I used the upper bushing from the PS IC and trimmed them down to fit.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8851_zps3c8501bb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8851_zps3c8501bb.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8852_zps0984b1c3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8852_zps0984b1c3.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8853_zps3d8d9f03.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8853_zps3d8d9f03.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 05, 2013, 08:48:36 PM
I had done the A/C condenser trimming, and remount last year.  So I just removed it to check everything and make sure it wasn't rubbing on anything.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8863_zpse8f6b7fb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8863_zpse8f6b7fb.jpg.html)

Here you can see how much room I have on either side of the IC and those brackets.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8857_zps81891173.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8857_zps81891173.jpg.html)

Trimmed the top of the upper mounts on the IC....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8854_zpsc83e3108.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8854_zpsc83e3108.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 05, 2013, 09:00:54 PM
You can also see in the A/C condenser pic the trimming I had to do on the rad support.  Tried to keep it to a minimum.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8863_zpse8f6b7fb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8863_zpse8f6b7fb.jpg.html)

And the IC in place...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8859_zpsc222732f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8859_zpsc222732f.jpg.html)

Had to trim this lug off to clear the A/C line connection....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8865_zpsc0e0f83b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8865_zpsc0e0f83b.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 05, 2013, 09:07:13 PM
And it's basically in place now.  Just need to fab up the mounts.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8868_zpsa0c524d9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8868_zpsa0c524d9.jpg.html)

The lower mount will use the stock pocket and then run over to the bracket and bushing.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8870_zps2ddb4afd.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8870_zps2ddb4afd.jpg.html)

And the upper mount will use the original bushings from the OEM IC.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8871_zps512aae38.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8871_zps512aae38.jpg.html)

I will slot the aluminum tag and slip these in like the original ford bushings.  Then fab up some brackets to hold it in place.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8872_zpsac69cf3f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8872_zpsac69cf3f.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on December 05, 2013, 09:15:43 PM
Good job. Couple bolts and it will be done.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 11, 2013, 08:21:59 PM
The 5th Gear shift rail came in today...Once again a great piece from Quad4x4!!  Got it, and the 5th gear all installed today.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8902_zps419bd41a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8902_zps419bd41a.jpg.html)

Then it was time to install the 5th gear nut.  Here is the order of things that I installed.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8901_zps130ee36b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8901_zps130ee36b.jpg.html)

-New 5th Gear.  
-Then split washer set-up to help hold 5th gear in place should nut back off.
-Concave washer
-New 5th gear nut with brass pins to torque down onto the treads to lock in place.
-Then the splined lock for the 5th gear nut.

With all of this I hope to never have any 5th gear issues...;)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 11, 2013, 08:36:50 PM
So I go ahead and install everything.  Here's how the split washer looks when installed.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8903_zpsf7f9dc88.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8903_zpsf7f9dc88.jpg.html)

Used red loc-tite on threads and nut to help hold things in place.  I finish torquing everything down...which is a chore if your doing it by yourself on the shop floor, and have no way to secure the tranny....:(  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8905_zps3134a7dd.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8905_zps3134a7dd.jpg.html)

I then realize I may have an issue with the split washer set-up.  And the loc-tite had got into the area where the brass pins were to sit and was not allowing them to be torqued down properly. :(  So out comes the heat, and I have to pull everything apart again.  That red Loc-tite is some evil stuff!!

Finally got it all apart, and cleaned up.  That too is a chore. Once clean I did a dry trial run....got everything the way I wanted it and pulled it apart again.  This time I had a friend come and help with the nut torque down.   A little better...but not much.

During the assembly this time I installed some small pieces of paper towel into the bore for the brass pins.  So it would soak up the loc-tite.  Then once the nut was torqued down I used my small picks to pull out the paper towel and install the brass crush pins...and torqued them down.  

But before you do that you need to line up the nut with the splined nut lock.  I had to play with it on the splines until I found a spot where it was just a hair out of alignment.  Then I used the 5th gearnut tightening tool, and a rubber mallet, to beat the nut into alignment.

Now it's all done for good!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8908_zpsf53acc00.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8908_zpsf53acc00.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 11, 2013, 08:44:21 PM
Then it was time to install the new 4wd tailhousing.  I bought a new cast unit...since I couldn't find a new/used aluminum unit.  I would recommend you scratch the inside of it if you end up buying one.   I used a large screwdriver.  I had a lot of small metal debris that was stuck in the paint.  It would have eventually worked itself free and could have cause issues internally.

Once cleaned up I realized it did not come with any dowel pins.  Good thing I still had the 2wd tailhousing.  Few hits with hammer and punch had them out and ready to install in the 4wd housing.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8910_zps555238c4.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8910_zps555238c4.jpg.html)

It wash then time to install the top cover, and side PTO plates.  Once the top was on I stalled the shifter and ran through the gears.  Everything seems to shift fine.

All done.....Finally!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8916_zpsb889c2f9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8916_zpsb889c2f9.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on December 11, 2013, 08:50:44 PM
Looks good to me!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 12, 2013, 07:45:23 AM
Thanks!! (http://www.moparfins.com/forum/smileys/smiley20.gif)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 16, 2013, 09:06:04 PM
Got the mounts made for the intercooler.  I will let the pics tell the story here.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT9004_zps7d28b1d7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT9004_zps7d28b1d7.jpg.html)

I decided to mount it without the upper and lower bushings.  I installed it with the lower bushings and the IC had way too much movement.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT9005_zps617fb442.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT9005_zps617fb442.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT9007_zpsd0df584f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT9007_zpsd0df584f.jpg.html)

I also had to notch the center support just a bit to gain a little extra room.  But that's par for the course. ;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT9008_zps1ad2460d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT9008_zps1ad2460d.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 16, 2013, 09:08:49 PM
All done, pretty happy with the way it turned out.  I just need to throw a little flat black on it and it will be ready to install.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT9012_zps63002f5c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT9012_zps63002f5c.jpg.html)

Nice and tight...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT9013_zps4734df7b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT9013_zps4734df7b.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 16, 2013, 09:14:29 PM
And I cleaned up the transfer case shifter.

Old....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT90022_zps12c9b5eb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT90022_zps12c9b5eb.jpg.html)

And all the parts clean and painted....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT9006_zpsd92643c1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT9006_zpsd92643c1.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on December 16, 2013, 09:20:13 PM
Curious

I'd be happy with a 2WD 4 door 1st gen
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 19, 2013, 08:37:17 PM
Quote from: POLARACO
Curious


 I Don't want to know....(http://www.moparfins.com/forum/smileys/smiley5.gif) 

Figure I'll be in the $20K range when it's done and painted.  But at least I don't have a truck payment, and it's all paid for.(http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 19, 2013, 08:37:27 PM
Yesterday I got the oil pan gasket, and rear main seal done.  Nothing really special about it...other then the 36 frackin bolts for the oil pan!!!

I wanted to get that done before I dropped the motor back in the truck.  So today I did just that....motors back in.  I also got all the clutch and bell housing assemblies installed as well.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0016_zpsbf66a5e8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0016_zpsbf66a5e8.jpg.html)


Hope to have the tranny in tomorrow, and get the tranny mount located so I can drill all the holes in the frame for it.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 19, 2013, 08:40:28 PM
And I'm seriously cheesed off as well.  I've been searching for days for the transfer case shifter, boot and ring.  Can't find it anywhere.  I still have a few weeks before I'll be close to needing it...so hope it shows up before then. [redface]


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on December 19, 2013, 09:12:44 PM
You must have my garage.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on December 19, 2013, 09:18:06 PM
Steve, what garage are you talking about? Have you one that is now free of all projects that could be used for a real single project, or the tarp shed/garage?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 20, 2013, 07:08:36 PM
Well I woke up to snow this morning....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0019_zpsf22566cd.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0019_zpsf22566cd.jpg.html)

But I still went ahead and got the tranny in today.... ;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0021_zpsc7616974.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0021_zpsc7616974.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0022_zpsa2f4d76b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0022_zpsa2f4d76b.jpg.html)

I was freezing and soaked after that...so I called the rest of the day a "Snow day".  Went sledding with my daughters instead....:)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on December 21, 2013, 04:01:37 PM
Quote from: dana44
Steve, what garage are you talking about? Have you one that is now free of all projects that could be used for a real single project, or the tarp shed/garage?

I have a real garage too!  It's loaded with tools, parts, equipment. . . .  All Isles
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on December 21, 2013, 04:10:38 PM
Quote from: thrashingcows

I was freezing and soaked after that...so I called the rest of the day a "Snow day".  Went sledding with my daughters instead....:)


But you said you were soaked and tired!  (http://www.moparfins.com/forum/smileys/smiley2.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on December 21, 2013, 05:02:06 PM
Soaked and tired can be fixed, playing with the kids is more important. Always. They grow up so fast. Heck, I can still remember my daughter waving her diaper at the garbage truck. Today, her older sister gave her her second (more successful) manual transmission driving lesson on flatter Arizona roads and was successful. No, soaked and tired can be warmed and caffeined up to play with the kids any day in my book.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on December 21, 2013, 05:27:33 PM
That's why the wink
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 28, 2013, 04:27:03 PM
Well now that Christmas is over....I have been able to work on the truck the last couple days.  

Got the tranny cross member all pulled apart...cleaned up...and painted.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0052_zps0c14d7ab.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0052_zps0c14d7ab.jpg.html)

As well as several hours cleaning nuts,and bolts on the wire wheel.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0051_zps45a61a5d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0051_zps45a61a5d.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 28, 2013, 04:35:17 PM
And today I got the tranny mount in...mostly.  I had hoped that at least a couple of the existing holes would line up with the bracket....nope.  So will have to drill all 12 of them.

 I still need to get the upper brackets in, and then those 6 holes drilled.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0054_zpse9f17fd9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0054_zpse9f17fd9.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0055_zpse1e8d722.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0055_zpse1e8d722.jpg.html)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: 300rag on December 28, 2013, 05:57:39 PM
I sure hope your wife isn't looking for her ironing board.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 28, 2013, 06:52:36 PM
Quote from: 300Rag
I sure hope your wife isn't looking for her ironing board.

(http://www.moparfins.com/forum/smileys/smiley36.gif)

Nope those are used from the second hand store.  I have two of them.  Love them!!  They are great, quick work benches!




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on December 29, 2013, 07:50:00 AM
Nice to see poly bushings instead of rubber. Looks great!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on December 29, 2013, 01:35:32 PM
(http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: azblackhemi on December 29, 2013, 04:07:28 PM
Great idea! I shop at the thrift stores on half price Saturday for car wash towels and quilts for padding freshly painted parts. Buying them at half price is cheaper than laundering them.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 03, 2014, 09:44:24 PM
Today I got the cab mounts swapped.  Turned out the crewcab already had a set of poly bushing cab mounts.  But since I had new ones...and did not know how old the old ones were...I decided to swap them in anyway.

Used some big dunage to lift one side at a time.  The opposite side was loose...but still bolted in place. And then Just list it high enough to wrestle the old bushing out.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0001_zpse2f39c8e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0001_zpse2f39c8e.jpg.html)

New ones in and bolted down.  I spent a few minutes making sure the cab was square on the chassis. Checked measurements from side to side, and front to back.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0006_zps93eaf316.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0006_zps93eaf316.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 03, 2014, 09:56:25 PM
And I got the transfer case installed.  Went pretty smooth considering it was just me and my floor jack, on a sloping driveway....;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0028_zps4d824141.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0028_zps4d824141.jpg.html)

And then I decided to dismantle and clean my front bumper.  Got all the black plastic pads off...and then polished it up as best I could.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0013_zps00d5afd7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0013_zps00d5afd7.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0015_zps09678bfc.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0015_zps09678bfc.jpg.html)

Will have to repair a couple of the plastic pockets the studs slip into...but shouldn't cause me too much grief.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on January 04, 2014, 05:37:48 AM
Very nice. Keep up the good work.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 04, 2014, 07:48:08 AM
Quote from: dana44
Very nice. Keep up the good work.

Thanks...will do!! (http://www.moparfins.com/forum/smileys/smiley2.gif)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 04, 2014, 07:16:25 PM
So today I decided to clean the back side of the front bumper...why?...cause I didn't like all that rust.  And sometimes I can't help myself...[dummy]

Before...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0009_zps61a11090.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0009_zps61a11090.jpg.html)

After...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0025_zps1af0db85.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0025_zps1af0db85.jpg.html)

I will give the back side a coat of flat black paint...will help keep the rust monster at bay for a while. ;)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 04, 2014, 07:25:23 PM
I then concentrated on getting the removable tranny tunnel cut for the shifter...and then clean up the opening, and open it up enough for the transfer case shifter.

Had to measure and re-measure to make sure I got my shifter hole in the right spot.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0001_zpsc194aa54.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0001_zpsc194aa54.jpg.html)

Mark out the areas I was going to cut...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0002_zpsc5c59104.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0002_zpsc5c59104.jpg.html)

Then it was cover the tranny and start cutting.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0003_zps461c56dc.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0003_zps461c56dc.jpg.html)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 04, 2014, 07:51:45 PM
Now that I had lots of room it was time to install the Advanced Adapter transfer case shifter bracket...and hardware.

You have to use the longer bolts supplied to mount to the tranny...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0030_zps092416c8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0030_zps092416c8.jpg.html)

Bracket installed....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0031_zpsb16cb422.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0031_zpsb16cb422.jpg.html)

Then tried to install the shifter....NOPE aint going to fit!! Isn't this just my luck... :(

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0032_zps120f939c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0032_zps120f939c.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0033_zps95cef53e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0033_zps95cef53e.jpg.html)

Turns out that the gated transfer case shifter off a Cummins/A518 auto combo is about one inch too wide....or wider then the Getrag combo. So it was sitting tight against the outside edge of the TC shifter hole.  And under the truck the length of the shaft had it sitting tight against the floor board.

Here's the stock set-up.  You can see the inside gated shift area...this is where I need the shifter to be.  So now I have to remove 1" from everything so it will all work.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0035_zps91135385.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0035_zps91135385.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 04, 2014, 07:58:52 PM
So I dismantled everything and was trying to figure out what I could do.  I needed an inch out of the main plastic body....I was going to cut at it with my cut off wheel, but then I thought..."Hey a hot thin blade would melt through the plastic like a hot knife through butter!"

So I decided to heat up and exacto knife blade and slowly work my way around the block.  I had first scribed a line all the way around so I knew where to melt. ;)

All done....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0036_zpsf1c25980.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0036_zpsf1c25980.jpg.html)

Then I mocked it up so I could see where I needed to hack out the one inch out of the main shaft.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0037_zps0288f202.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0037_zps0288f202.jpg.html)

Once cut I used a couple rare earth magnets to hold it mostly square so I could tack it.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0038_zpsa32aac45.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0038_zpsa32aac45.jpg.html)

All welded up...then used a flapper disc to clean it up.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0039_zps06e28397.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0039_zps06e28397.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 04, 2014, 08:03:14 PM
I then had to figure out a way to hold the main body in place.  The original piece had little plastic pins that went through the bracket and held it square, and in place.  But since I cut it down I no longer had these pins.  I decided that there was enough material on the back side that I could drill it with a very small bit, and then use a couple small screws to hold it in place.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0040_zps426a0844.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0040_zps426a0844.jpg.html)

It's not like this pad is under load.  Just don't want it to flip out of alignment.

Then it was re-assembly time!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0041_zpsbd44bb61.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0041_zpsbd44bb61.jpg.html)

Now that looks a lot better!!


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 04, 2014, 08:06:03 PM
Now to install it in the truck and see how it looks....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0042_zps410a821a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0042_zps410a821a.jpg.html)

Sure looks like it's in a better spot...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0043_zps50418419.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0043_zps50418419.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0044_zpsd37c0805.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0044_zpsd37c0805.jpg.html)

Much happier with that!!


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 04, 2014, 08:14:57 PM
Then it was onto the rod from the shifter to the TC.  This did not go easily either.  I messed around with it in all types of orientation and with the bushings it came with.

Turned out I needed to modify two of the bushings.  It came with three, but only needed two.

Here's what they looked like....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0045_zpsb0fb37b4.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0045_zpsb0fb37b4.jpg.html)

Here is where I used them. The center one I used on the pin that goes through the main shifter hole.  It takes up the slop, but when I installed it as I received it, it did not allow the shaft to go through far enough to get the cotter pin through.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0046_zpse15ceaeb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0046_zpse15ceaeb.jpg.html)

And the one of the far right I had to shorten.  The adjustable clasp had too mush slop for my liking.  So I used the shorten bushing as a spacer on the top.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0047_zps210fbfd7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0047_zps210fbfd7.jpg.html)

So where does the main shifter arm need to sit?  does it sit all the way forward, or back, or half way in between?  I don't have a pic of the shifter before I removed it, and can't recall where it needs to be set-up.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on January 04, 2014, 09:30:51 PM
Good job, but location? Not a clue.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 05, 2014, 08:41:20 AM
If it doesn't matter on the location, I would imagine the position that fits best to the floor and boot.  No?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on January 05, 2014, 09:54:36 AM
That makes sense, the throw of the handle does the high and low, right, and the amount of pull/push just determines the end result, it is either in or not, nothing else.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 09, 2014, 07:57:31 PM
Got a few things done today.  Installed the skid plate.  Had to drill 2 more holes up into the frame....but at least they were not inside the frame. ;) :)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1005_zpsd0a2bf40.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1005_zpsd0a2bf40.jpg.html)

The painted the inside of the front bumper, and wire wheeled clean all the bumper brackets and nuts and bolts.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1004_zps8f1a518a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1004_zps8f1a518a.jpg.html)

I was going to install the front shocks...but got to looking at the lower mounts for the shocks.  I decided that they were too ugly and rusty....so I removed them, wire wheeled them clean, and painted them up.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8805_zps09efd657.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8805_zps09efd657.jpg.html)

Will install them, and the new shock tomorrow.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 09, 2014, 08:00:29 PM
I then decided I would start welding up the holes in the inner fenders.  Had a few extra ones added over the years. ;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1002_zps5302051f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1002_zps5302051f.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1006_zps337c693c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1006_zps337c693c.jpg.html)

Hope to install the support/stiffening brackets I removed from the original 93 fender tomorrow as well.  


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 09, 2014, 10:18:09 PM
You could have just bolted stuff up to the holes.  (http://www.moparfins.com/forum/smileys/smiley5.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 10, 2014, 10:47:04 AM
Quote from: POLARACO
You could have just bolted stuff up to the holes.  (http://www.moparfins.com/forum/smileys/smiley5.gif)

These are from the 84 crewcab, and they had a ton of holes I would never use.  And I hate spray working it way in through the holes.

I kept what I knew I'd be using.  And since the 93 has a lot more things bolted to the inner fenders...I now have a relatively clean slate to attach things too.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 10, 2014, 01:30:52 PM
I was kidding!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 17, 2014, 07:29:08 PM
Working off and on on things the last few day, between work and life...Man they really get in the way...[laugh]

Finished getting the support brackets welded on the inner fenders.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT10062_zps3560dc10.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT10062_zps3560dc10.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1008_zps5ce7e6f6.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1008_zps5ce7e6f6.jpg.html)

Then got them cleaned up, sanded and primed.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1023_zpsa8d4a313.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1023_zpsa8d4a313.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1022_zps497defe6.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1022_zps497defe6.jpg.html)

And today I got some white paint sprayed on.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1046_zpse2e2b522.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1046_zpse2e2b522.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 17, 2014, 07:40:22 PM
The black pads for the front bumper are held in place by 8 small square headed bolts that sit in pockets on the back side of the pads. They then protrude through the bumper and have a nut to secure it.  

Well my front bumper was extremely rusty on the back side, and I ended up wrecking 4 of them. The plastic that makes up the square head on the bolt cracks and falls off.  So I was trying to figure out how to replace them.  Finally came up with an idea.

Cut some 3/4 flat bar into squares...then drilled 1/4 hole in each one.  Then found some old bolts and cut the heads off.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1014_zps44eba23d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1014_zps44eba23d.jpg.html)

Then welded the studs onto the flat bar squares.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1016_zps639e677d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1016_zps639e677d.jpg.html)

They look very similar...and function better then the originals...IMO. ;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1017_zps671e26f6.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1017_zps671e26f6.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 17, 2014, 08:19:42 PM
I also ordered all the spicer U-joints for my front drive shaft...which will need to be shortened.  The donor 93 4wd was a Cummins/auto truck...and I have a NV4500.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1027_zps92ae8cd6.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1027_zps92ae8cd6.jpg.html)

Quick clean up with the wire wheel...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1028_zpsf72ba8da.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1028_zpsf72ba8da.jpg.html)


Anyway I went to disassemble the Cardan joints and found that there was no clips..WTF!!  I did some searching on line and could not figure out exactly how they were being held in.

I noticed these white nubs...which I originally thought might be small bumpers for if the cardan joint got too close to the U-joint on rotation?  Turns out those nubs were the leavings of the liquid plastic that was squeezed into the castings and caps.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1030edit_zpsb6ceecef.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1030edit_zpsb6ceecef.jpg.html)

It requires lots of heat to melt the plastic.  It then comes squeezing out of the holes like long white worms.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1041_zps8714d9b9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1041_zps8714d9b9.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 17, 2014, 08:25:04 PM
After battling those 2 joints for a hour or so I finally got everything apart.

Here's a pic of the plastic I cleaned out of one of the U-joint caps onthe driveshaft.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1043_zps92797597.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1043_zps92797597.jpg.html)

And you can see the grooves in the driveshaft yoke, and the U-joint cap.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1044_zpsbf9ccf53.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1044_zpsbf9ccf53.jpg.html)

I was telling a friend of mine about this and he mentioned that GM/Chev has been using this type of U-joint securing method for a long time...it was the first time I had EVER seen this!

Glad the new joints come with clips. ;)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 17, 2014, 08:52:25 PM
That's where a real hot wrench comes in handy.  Probably should have taken it to work and have the boys do it in 3 minutes.  Take longer to start up then it would to heat the epoxy
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 18, 2014, 06:22:32 AM
Quote from: POLARACO
That's where a real hot wrench comes in handy.  Probably should have taken it to work and have the boys do it in 3 minutes.  Take longer to start up then it would to heat the epoxy

I use the yellow bottle on the hand held torch...it's an oxy/acet mix I believe.  It get hot in a hurry...maybe not as hot as a true oxy/acet set-up...but good enough for the garage/shop.(http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: firedome on January 19, 2014, 05:34:23 AM
Nice work Brian!

You have green grass there this time of year??? I thought you were in the frozen tundra up there!


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 19, 2014, 06:48:00 PM
He lives in Florida.  Don't let him kid ya  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 21, 2014, 06:02:09 PM
Quote from: POLARACO
He lives in Florida.  Don't let him kid ya  LOL

(http://www.moparfins.com/forum/smileys/smiley36.gif)


We get more rain then anything for our winters here on the "Wet Coast" of Canada....(http://www.moparfins.com/forum/smileys/smiley2.gif)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 21, 2014, 09:18:51 PM
You gonna start bragging like Azblack?  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: azblackhemi on January 22, 2014, 05:04:10 AM
 (http://www.moparfins.com/forum/smileys/smiley17.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 24, 2014, 09:23:34 PM
Been up to a few things on the crewcab.

Go the cowl crack area bracing welded in.  I was originally going to make big patch panels to cover everything...but I was down at the parts store and spotted some HD band strapping.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8834_zpsad6ba4b2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8834_zpsad6ba4b2.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1025_zps36e90934.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1025_zps36e90934.jpg.html)


The nice thing about this strapping is you could tack one end...then beat it into shape and move along.  Worked really well....I'm pretty happy with the way it turned out.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1001_zps3140d2bd.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1001_zps3140d2bd.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1004_zpsa2ca3270.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1004_zpsa2ca3270.jpg.html)

And the holes in the strapping were big enough to have the fender mounting bolts go through...so a little added tie into the fender


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 24, 2014, 09:24:17 PM
Cleaned up the access plate area at the bottom of the rockers.

Before...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1012_zps6d6b5f2d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1012_zps6d6b5f2d.jpg.html)

After...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1013_zpseec27dd8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1013_zpseec27dd8.jpg.html)

I will spray on some new undercoating before I put the front end back together.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 24, 2014, 10:03:34 PM

I can not even tell you how much I hate PHOTOBUCKET right now!!  I've
been uploading photos and it has been randomly placing them wherever in
my folder.  I re-organize and it then shuffles them around AGAIN!(http://www.moparfins.com/forum/smileys/smiley7.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 24, 2014, 10:06:33 PM
When i got the truck originally the box was missing the two mounts on the LH side of the frame.  In fact the box was welded to the frame!  I eventually removed and cleaned up the area, and made my own brackets.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6513_zps137e25e1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT6513_zps137e25e1.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT6544.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT6544.jpg.html)

But since I had the original brackets form the donor 93 I figured I way as well install the proper brackets.  I had to re-drill because these brackets used 3 mounting holes. I then installed them with the same 1/2" x20 Grade 8 Flange head bolts and matching flange head stover nuts....overkill...probably, but I feel better knowing it's this way.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1007_zpse5b05509.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1007_zpse5b05509.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1008_zps49a7d269.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1008_zps49a7d269.jpg.html)

I also ordered enough bolts to replace the ones on the LH rear body mount.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1006_zps5d604a5c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1006_zps5d604a5c.jpg.html)

 Not sure what happened in the crewcabs life to cause the two box brackets, and this body mount to be missing and replaced?  But now at least things are closer to the way it should be.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 24, 2014, 10:12:09 PM
I also ran the brake lines.  Found out that with the 2nd Gen adapter and starter to run the NV4500 that the brake line would be in right between the starter and the frame rail...with little to no clearance.  So I had to re-route it along the top of the frame and then down once under the cab.

Got the RWAL valve mounted, and the lines bent up for it.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1010_zpsbdee3e31.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1010_zpsbdee3e31.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 24, 2014, 10:20:03 PM
And I cleaned up and repaired a bunch of the body /chassis wiring.  Had to modify the box a wee bit to get the taillight connector through the hole down inside the box.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1017_zps6fcdf039.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1017_zps6fcdf039.jpg.html)

Seems this hole got bigger probably whenever they decided to go with the big water tight 4 wire connection.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1018_zps4f670786.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1018_zps4f670786.jpg.html)

So a little pounding with a bar opened it up enough to get the wiring connector through.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1019_zps75436aaa.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1019_zps75436aaa.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 24, 2014, 10:57:25 PM

You can upload them direct if you sized them right.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 25, 2014, 07:11:01 AM
Thanks Steve...I fixed the propblem.  I still really HATE photobucket though....(http://www.moparfins.com/forum/smileys/smiley7.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 25, 2014, 10:49:09 AM
You didn't paint the frame?
Rust proof the crap out of that now.  We'll be able to bury you in it.  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 25, 2014, 11:30:00 AM
Quote from: POLARACO
You didn't paint the frame?

No...we don't really get winter here.  Couple weeks of snow...maybe...but usually gone in a few days.  I always clean and wash the under carriage and frame a couple times a year.....so that helps keep it in good shape as well.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on January 25, 2014, 12:57:44 PM
Getting a lot of the little things done, and yes, photobucket sucks.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 25, 2014, 04:28:30 PM
But But you painted everything else!  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 25, 2014, 06:08:22 PM
Quote from: POLARACO
But But you painted everything else!  LOL

Not quite everything....(http://www.moparfins.com/forum/smileys/smiley2.gif)(http://www.moparfins.com/forum/smileys/smiley36.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 08:27:58 PM
Ok I'll try again tonight....Have I mentioned how much I hate photobucket!! [verymad]

I have been working on the crewcab...just been too busy to update regularly.

So here's what I've gotten done in the last week or so.  I got the fuel tank and lines in and hooked up.  

I did do one little modification when installing the fuel tank straps.  Since the 84 chassis uses a little different tank strap then the later ones.  The 84 straps are bolted to the bottom of the frame rail with two bolts and nuts, behind the fuel tank. The problem with this set-up is that you can not remove those nuts since the bolts will spin once loosened.

So my solution was to weld a small piece of flat bar between the bolts.  Thus making a simple U-bolt that can be unbolted anytime.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1045_zpsd856ef1c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1045_zpsd856ef1c.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 08:36:16 PM
The nylon fuel lines were pre-bent for the clubcab chassis....but I made them work.  Used a number of old heater hose zip tied to them to make sure they would not rub on anything.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0001_zpsf492a5bf.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0001_zpsf492a5bf.jpg.html)

Had to lengthen them 11". Staggered my cuts and used 5/16" brake line make the splice.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0005_zps18ea7e4e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0005_zps18ea7e4e.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0007_zps214dde57.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0007_zps214dde57.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 08:42:37 PM
Removed all the dash cluster and wiring.  Also managed to wrestle out the 7 5/16" bolts from under the window seal.  Got the firewall all stripped out on the drivers side.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0011_zps3cd83fc9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0011_zps3cd83fc9.jpg.html)

Man I hate people who do hack work!![verymad]  Just makes more work for me to re-do it properly.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0012_zps4c16966d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0012_zps4c16966d.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0013_zps6566d20f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0013_zps6566d20f.jpg.html)

Going to finish stripping the dash out, then I can weld in new material and re-shape the holes, and add the ones necessary for the 93 wiring and such.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 08:53:44 PM
Also got my driveshafts all done.  I ordered all new Spicer U-joints, Cardan joint rebuild kit, and carrier bearing. 

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1049_zps02f2fbf9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1049_zps02f2fbf9.jpg.html)

Dismantled everything and cleaned it all up the best I could.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1048_zps7faccb96.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1048_zps7faccb96.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1047_zpsa0b8ca55.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1047_zpsa0b8ca55.jpg.html)

I called my local driveline shop and asked them how they wanted me to measure things.  Turned out I needed 29.75" length for the front drive shaft.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1050_zps47bb299f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1050_zps47bb299f.jpg.html)

Then the 2 piece rear I needed 19" for the shaft from transfer case to  center line of the carrier bearing.  Then 75" from carrier bearing center line to rear axle.  They ended up having to replace both ends on the long driveshaft.  The bores for the cups were worn out.


(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT1052_zps78d56bd0.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT1052_zps78d56bd0.jpg.html)

They did a very nice job on everything.  Not cheap getting 3 drive shafts done.  Shorten front one...then lengthen both rears, with 2 new ends.  But they did install all the U-joints and and hardware for free.  But at least everything is New and ready for another 260K Km's.... ;)



thrashingcows2014-02-07 02:05:22
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 09:01:09 PM
Little problem I had.  I have been trying to find the Moog K7282 axle bumpers for a long time now.  Tried all the local jobbers...Canada and USA.   I eventually thought I had found some through Jegs.  Their website said they had a bunch in stock....so I went ahead and ordered them.  I received notice that they were back ordered.  This went on for almost 2 months before I cancelled the order.

I then was poking around my local Lordco and noticed some axle bumpers in the "Help" section.  They sure looked like the ones I needed.  I had the parts guy run the number...they were for 80-93 ramcharger....yup should work!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT8837_zps5e27143e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT8837_zps5e27143e.jpg.html)

So if you are looking for these...just look/order these ones and you should be good to go!!


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 09:14:13 PM
Pulled apart the front of the motor to check the KDP and case bolts.  Case bolts were still nice and tight.  I tabbed the KDP with an old U-joint axle strap...someone mentioned doing this so I thought I'd try it.

Little work with the rat file to open up the hole.  Then cut and grind until it fit perfect.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0023_zps22171e4c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0023_zps22171e4c.jpg.html)

And a little trick I use to make sure I get the front timing case cover bolts back in the right location.  Since there are short, and long bolts.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0018_zps01e007d5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0018_zps01e007d5.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0020_zpsdcfd091b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0020_zpsdcfd091b.jpg.html)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 09:25:15 PM
Then it was on to the installation of the fluidampr.  Since this is a 93 motor I had to use the CPS relocation bracket.  I looked on-line and could not find any pics of how this all went together...and the instructions that came with the kit were vague at best!

So I'll post up on what to do.

Once the timing case cover crank seal has been replaced, and the cover is back in place, you can install the fluidampr with the 4 - 15mm crank bolts.  Then remove the two bolts on the lower LH side of the motor.  The instructions that came with the CPS relocation kit were not very clear here.  These are the ones you need to remove.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0025_zps364a262c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0025_zps364a262c.jpg.html)

Then install the new spacer/bolts.  These are 19mm.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0026_zps34d4d5f1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0026_zps34d4d5f1.jpg.html)

And now the main bracket.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0027_zps5936ccfb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0027_zps5936ccfb.jpg.html)






Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 09:38:17 PM
Now it should have been easy and just re-install the Crank Postion Sensor (CPS) and adjust the gap... 0.049 to 0.051, and your done.  Nope not for me!

Turned out the CPS I have on my motor is a little different. I tried every way possible to get things to line up.  I was just not able to get any clearance between the CPS and the fluidampr.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0029_zpsce8c6b78.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0029_zpsce8c6b78.jpg.html)

Turned out that after searching pics on-line I think the mounting bracket changed at some point.

Here's my CPS and bracket....after my modification with the rat file.  


(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0030_zpsbc62a550.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0030_zpsbc62a550.jpg.html)

And I was finally able to get my .050" air gap.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0032_zps85d0f38d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0032_zps85d0f38d.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 09:43:46 PM
Oh and one more thing with the fluidampr install.  Make sure you put your belt over the crank pulley before installing the CPS relocation kit.

Also While I had the front of the motor apart I decided to pop out the water pump for an inspection.  Glad I did because I could see that there had been coolant weeping out of the water pump.  So I tossed in a new one I had in the garage.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 10:06:57 PM
If your installing a fluidampr on a non-IC motor (89, 90, early 91) then you should be OK with fan blade clearance, but double check first. On the 91.5 to 93 motors you are more then likely going to have clearance issues between the fan and fluidampr.

I had a new fan from a 2nd Gen on my 89 motor, with a new clutch assembly.  I decided to compare it to the original assembly I pulled off the 93 motor.  Turned out the fans are the same, but the clutches are a bit different.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0002_zps0624d96a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0002_zps0624d96a.jpg.html)

but the distance between the end of the clutch bolt, and the body of the fan was different.  The OEM 93 unit was a tad longer then the 2nd Gen fan and new clutch.  The difference was about 0.20" longer for the 93 clutch.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0003_zps76b582eb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0003_zps76b582eb.jpg.html)

So I swapped the fans around and used the OEM 93 clutch.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 10:15:57 PM
So I first modified a washer that was about 0.125" thick.  Wish I had a milling machine...I had to resort to rat files, and drum sand discs, and round flapper discs.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0001_zps0878cacb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0001_zps0878cacb.jpg.html)

Once installed the fan was just kissing the fluidampr.  So I needed a thicker washer.  I found one spot welded to the old 2wd front cross member from the crewcab. Had to drill out 3 spot welds.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0004_zps745e80a3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0004_zps745e80a3.jpg.html)

Then used a 60 grit flapper disc on my 4.5" grinder to slowly turn down the outside diameter....You can see it was a fair amount!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0006_zps6b657089.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0006_zps6b657089.jpg.html)

This washer was about 0.20"...and was perfect!!


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 10:18:25 PM
Washer goes between pulley, and fan clutch nut.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0007_zps87c5eb72.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0007_zps87c5eb72.jpg.html)

And lots of clearance now....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0008_zps2170e136.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0008_zps2170e136.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 10:25:53 PM
Thought I had a fix for the E-brake system.  The axle cables from the 93 are a lot longer then the 84 cables....where they come through the bracket on the driver side.

I swapped over the 93 clubcab e-brake assembly and main cable, but was still about 14" short.  So I thought I would just add an extension to the threaded end of the E-brake cable.

I got some ready-rod, and a couple threaded couplers that I welded together.  Viola I thought I had it!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0006_zps151c6f6b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0006_zps151c6f6b.jpg.html)

Turns out that the axle cables don't pull the same length.  So the bracket twists and bent the ready-rod.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0007_zps29eeea87.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0007_zps29eeea87.jpg.html)

Guess I'll be swapping the E-brake cables from the 84 Dana 60 over the 93 Dana 70.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 06, 2014, 10:39:49 PM
I also ran into an issue with the flex line from the rear axle, up to the frame.  Originally the flex line ran up to the bracket with the female threaded end pointing towards the front of the truck.  But with the RWAL valve, this required the brake line to do a tight 180* turn.  

So to make things easier I had decided to install the flex line pointing towards the back of the truck.  Thus eliminating the 180* brake line bend.  But what happened with this is that once the fuel tank was installed it was hitting the flex line.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0009_zpscbc1a0d8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0009_zpscbc1a0d8.jpg.html)

I had been thinking about how to fix this, without bending new lines.  I finally was able to find a short 90* brake line fitting...or should I say a Tee...with a plug.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0011_zpsda4123c9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0011_zpsda4123c9.jpg.html)

Then I bent a spare bracket I had 90* so that the flex line would now be coming straight up.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0010_zps04478337.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0010_zps04478337.jpg.html)

And installed...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0012_zps393f4d7e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0012_zps393f4d7e.jpg.html)

The only thing I'd change is the tee.  If the male tube flare had been in the center port of the tee, then it would have been easier to get the brake line lined up.  And not have had to crank the begeezis out of the fitting I used to get it to line up.

Hopefully I don't have any leaks.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on February 10, 2014, 05:23:40 PM
Lots of good stuff there. Keep up the good work!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on February 10, 2014, 07:45:33 PM
Good idea.  You've been pretty crafty


I have a guest room.  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 28, 2014, 09:47:40 PM
I know I have not been updating regularly...trying to get the crewcab done ASAP.  I'm starting to jones hard on not driving my cummins.....[laugh]

I will try and update a bit over the next week or so...when I find time.

I stripped out the firewall and got the dash out of the truck...without having to pull the windshield...Woohooo!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0001_zpsba1fef80.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0001_zpsba1fef80.jpg.html)

And you can see some of the butcher job they did installing the clutch bracket, and the hole in the firewall.....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0002_zpsb485414d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0002_zpsb485414d.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0012_zps0a016dd7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0012_zps0a016dd7.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 28, 2014, 09:52:13 PM
So since I couldn't live with the butcher job, I decided to weld in some patches and then I could redo it properly.

I made up a one piece patch and welded it in.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0014_zps7c56f2f7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0014_zps7c56f2f7.jpg.html)

But after some measuring I noticed I needed a bit more material on one side.  So welded in another patch.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0016_zpsacf19c56.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0016_zpsacf19c56.jpg.html)

Now I needed to mark out the new hole.  Little thinking outside the box got me what I needed.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0017_zpsbffd7b92.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0017_zpsbffd7b92.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 28, 2014, 09:59:48 PM
Used a couple different size flapper discs on the die grinder to slowly open up the hole.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0018_zps76bf8ec1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0018_zps76bf8ec1.jpg.html)

And then a little rat file work on the wiring bulkhead area to get it into shape.  All done and ready for paint.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0022_zpsd38d7ad8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0022_zpsd38d7ad8.jpg.html)

And all painted up...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0026_zps659639f1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0026_zps659639f1.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0024_zps75a01732.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0024_zps75a01732.jpg.html)

Just a rattle can paint job...but much happier now that the firewall is repaired, and painted.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 02, 2014, 12:06:49 PM
I would have just put in a set of Flex-a-lite electric fans.  Thye save fuel and do a better job.  Maked allot of room in the front too.  Belt changes are a snap.
I admire your work and it brings back memories.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 04, 2014, 06:49:56 PM
Thanks Steve.  Yeah I might end up with electric fans anyway.  Hopefully the fan will not "flex" too much when under actual hot driving conditions. and hit the balancer.(http://www.moparfins.com/forum/smileys/smiley5.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 04, 2014, 09:05:39 PM
What else have I done in the last few weeks....well I converted my auto steering column to a manual one.

Here's what it took.  I pulled apart the steering column.  Here you can see the column shift mechanism I need to remove.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0071_zpse1efd1a4.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0071_zpse1efd1a4.jpg.html)

Once I tore the column down to the bare minimum I started cutting.  First was the bracket on the end of the column that the rod to the tranny hooks to.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0086_zps226aff44.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0086_zps226aff44.jpg.html)

Then rounded out the metal so it looks like it belongs.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0100_zps0498fa14.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0100_zps0498fa14.jpg.html)

Then snip off the indicator tab.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0087_zps618bd3de.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0087_zps618bd3de.jpg.html)

Then it was time to start the big cuts.  I first removed the shifter...just use a punch to drive out the pin.  Then start cutting....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0088_zpsa5d69c2e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0088_zpsa5d69c2e.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 04, 2014, 09:10:08 PM
When I bought my crewcab 4 years ago it came with a few extra parts.  Some of the parts were steering column covers.  I never really looked at them until I was going to do the 4wd conversion and use the 93 wiring and interior.  Turned out I had a set of manual shift steering column covers!!

Here's the two pieces...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0094_zps697ad9d9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0094_zps697ad9d9.jpg.html)

And a trial fit...close, but clears! It actually had a bit more room once screwed in place.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0096_zps7f5d41cb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0096_zps7f5d41cb.jpg.html)

And the column all back together....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/PICT0099_zps45fc2492.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/PICT0099_zps45fc2492.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 05, 2014, 12:03:24 PM
Quote from: thrashingcows
Thanks Steve.  Yeah I might end up with electric fans anyway.  Hopefully the fan will not "flex" too much when under actual hot driving conditions. and hit the balancer.(http://www.moparfins.com/forum/smileys/smiley5.gif)

There's a guy on eBay that sells returned fans.  I bought one and it was like brand new except for a few scratches.  They were like half price.  I don't have his name anymore. . .  Sorry
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 20, 2014, 10:14:31 PM
Good info though...Thanks Steve!!

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 20, 2014, 10:14:40 PM
OK I'm going to spend an hour or so and update a bit....

So I had to repair the drivers door.  The typical cracked lower hinge area.  Well it was previously repaired...poorly I might add.:(

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0108_zps925a13b8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0108_zps925a13b8.jpg.html)

And wire wheeled clean....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0111_zpsa2ececd1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0111_zpsa2ececd1.jpg.html)

I was first going to just open the cracks and weld everything up.  But after a bit of grinding I realized this was in WAY worse shape then I thought.  So I decided it would be easier to just cut out the offending area and start over.  Plus I needed to weld up the reinforcing area behind the outer sheet metal.

Kind of looks smug don't it....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0113_zpsef41b876.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0113_zpsef41b876.jpg.html)

Rear area welded up...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0116_zps9db0f35e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0116_zps9db0f35e.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 20, 2014, 10:21:40 PM
Rear area cleaned up and weld through primered....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0118_zps92814d9f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0118_zps92814d9f.jpg.html)

Then I had to make a new patch.  The original sheet metal is THIN...like .04"!! And the scrap metal I used was .048".  Anyway I had to mark out the holes...then drill and rat file them into shape.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0122_zpsabe71672.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0122_zpsabe71672.jpg.html)

And pretty much all welded up...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0125_zpsfdf5ee0b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0125_zpsfdf5ee0b.jpg.html)

And all finished up and painted....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0025_zpsbff14181.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0025_zpsbff14181.jpg.html)

Much better!!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 20, 2014, 10:32:42 PM
Then it was on to making a big reinforcing plate for inside the door.  Little trick to get in there and make a template...but eventually I got that template made.  Then I transferred it to some 1/4" plate and started cutting.  Wish I had a plasma cutter....that would have made it SOOO much easier!!

Anyway here is the finished piece.  I had to do a lot of drilling, and rat file work to get all those holes in the right spot.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0019_zps54957f1c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0019_zps54957f1c.jpg.html)

And a slight bend in the lower area....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0020_zpsd4d97aa7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0020_zpsd4d97aa7.jpg.html)

And installed in the door.....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0039_zpse691f30a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0039_zpse691f30a.jpg.html)

Hopefully this helps the lower hinge area to stay crack free for a few years.  Regardless I have a nice clean...uncracked...spare drivers door if I need it.  


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 20, 2014, 10:38:06 PM
I also installed new hinge pins and bushings.  Had to toss the original white lower hinge...it was twisted and bent from all that abuse.  So I grab a spare one I had and re/re'd it.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0038_zps1bf6f138.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0038_zps1bf6f138.jpg.html)

And just in case people don't know...the only difference between the LH (driver) and RH (passenger) side lower hinge is the direction the pin is installed.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0036_zps9410b1d0.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0036_zps9410b1d0.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0035_zps22947c10.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0035_zps22947c10.jpg.html)

The hinge is just flipped over to use on the other side of the truck.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 20, 2014, 10:41:36 PM
The lower rivet to hold the lower window stop bracket was loose.  So i decided to drill out all 3 rivets and remove the bracket.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0028_zpsc6ce5082.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0028_zpsc6ce5082.jpg.html)

I then installed some nuts and bolts.  Then welded the nuts to the bracket.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0033_zps71f4d074.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0033_zps71f4d074.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT00342_zpsa9a7b96c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT00342_zpsa9a7b96c.jpg.html)

Now if I need to remove the bracket for any reason, it will come out very easy. ;)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 20, 2014, 10:53:31 PM
The old donor 93 had been broken into at some point as well.  The drivers door lock was punched and bent up...but it still kind of worked.  I decided to tackle swapping out the main key tumbler with anouth spare lock I had.

Old lock...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0061_zps30097f8b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0061_zps30097f8b.jpg.html)

This is not a serviceable part BTW.  I had to carefully pry off the stainless front to get at the tumbler.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0081_zps231504d9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0081_zps231504d9.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0072_zps91814124.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0072_zps91814124.jpg.html)

Then do this all over again with my spare lock.  Once apart I discovered that the tumbler was damaged as well.  So i had to pull all the pins and swap them around.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0076_zps9fab9d11.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0076_zps9fab9d11.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0077_zps25d2e48c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0077_zps25d2e48c.jpg.html)

Once that was accomplished the fun part was getting the front stainless cover back on and that lip polled back over.  I have a small aluminum hammer...I decided this would probably do the trick.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0080_zps53d482f3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0080_zps53d482f3.jpg.html)

After a lot of fine tapping I go tit all secured again.  Here is the "new" lock...works like a charm!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0082_zps75633da3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0082_zps75633da3.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 20, 2014, 11:01:33 PM
I installed the cab roof lights.  I used the diagram, and measurements, that was posted up by Jim Lane....but did not like the location of the outside lights.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0050_zps1058f37e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0050_zps1058f37e.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0051_zpsf3fe8815.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0051_zpsf3fe8815.jpg.html)

So I moved the outer lights in a few more inches....Looks much better IMO.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0052_zps7d2e6e61.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0052_zps7d2e6e61.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0053_zps30f16852.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0053_zps30f16852.jpg.html)

Then it was the nerve wracking job to mark and drill the roof.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0061_zps9cf6151d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0061_zps9cf6151d.jpg.html)

And lights all installed.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0066_zps600a7346.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0066_zps600a7346.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 20, 2014, 11:15:02 PM
Now onto the interior roof panels. Here's what they looked like before.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0038_zps066b8182.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0038_zps066b8182.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0037_zpsa7d681eb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0037_zpsa7d681eb.jpg.html)

 I wanted removable panels like CE TEX has done in his truck.  So out came the cutting wheels.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0041_zpsa6c1eeb3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0041_zpsa6c1eeb3.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0042_zps9ac028bb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0042_zps9ac028bb.jpg.html)

Then it was sand and pain the inner roof.  I also masked and painted all the roof and pillar areas white too.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0047_zpsb6730313.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0047_zpsb6730313.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0046_zps9fa713fa.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0046_zps9fa713fa.jpg.html)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 20, 2014, 11:18:36 PM
Then it was time to drag out the spare crewcab roof I pillaged from the wreckers a few years ago.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0058_zpse8cccc7c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0058_zpse8cccc7c.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0057_zpsa9983983.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0057_zpsa9983983.jpg.html)

Then cut out the panels from this roof.  As you can see in 3rd pic where the one I removed from the crewcab is smaller then the one I removed from the wrecker roof.  This is so that the two over lapping lips will be used as the fastening area.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0093_zps62ced36c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0093_zps62ced36c.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0090_zps84d30164.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0090_zps84d30164.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0091_zps6f9550c7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0091_zps6f9550c7.jpg.html)

Then I cleaned and sanded and painted the removable panels.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0003_zpsac8829c9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0003_zpsac8829c9.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 20, 2014, 11:25:19 PM
Once all that was done it was time to insulate the roof.  I did a lot of research and came up with a product called mighty mat.  It has an aluminum coating on one side...and a glass matting? type layer on the other.  It does not hold moisture, or mold. And is about a 1/4" to 3/8" thick.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT00402_zpsba68b85b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT00402_zpsba68b85b.jpg.html)

Going into the roof.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT00412_zps5f1789d2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT00412_zps5f1789d2.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT00432_zpse9713ec0.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT00432_zpse9713ec0.jpg.html)

I then installed a second layer...fuzzy side down.  Then installed the removable panels.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0053_zps580b1bce.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0053_zps580b1bce.jpg.html)

All done for now.  It's nice and quiet now when you bang on the roof...inside and out!!  I want to get upholstered panels to cover all the screws...but that can come later.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 20, 2014, 11:27:42 PM
Alright I'm done for tonight.  Will update again soon...if I find some more time. ;)  I'm working like crazy trying to get the truck on the road...I'm getting darn close.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on March 21, 2014, 08:49:55 AM
Looks great, great hinge repair, lock repair, and the ceiling and insulation looks great. It is all the little things that take up the time to get things done quickly. Kind of gives you a little bit of respect on the cost a shop charges for a restoration job.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 21, 2014, 05:47:05 PM
Patience of a saint
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 21, 2014, 05:49:13 PM
Brian
OK with you if I put the link on http://www.igotacummins.com (http://www.igotacummins.com)?  You belong in there too.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 21, 2014, 10:09:53 PM
Quote from: POLARACO
Brian
OK with you if I put the link on http://www.igotacummins.com (http://www.igotacummins.com)?  You belong in there too.

Sure thing Steve.  This is why I post up this stuff....to share with my friends, and to help other out. ;)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 21, 2014, 10:17:06 PM
I decided to try and clean up my cargo light.  As many of you know they tend to yellow with age.  But I got mine darn near new looking with a bit of elbow grease.

First was to use an SOS pad to try and get most of the yellowing gone.  This is what it looked like after the SOS pads.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0086_zps83b65e9a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0086_zps83b65e9a.jpg.html)

Then I polished the lens with some mothers mag wheel polish....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0087_zps49528db8.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0087_zps49528db8.jpg.html)

Next was the Meguiars plastic cleaner....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0089_zps2c7d8665.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0089_zps2c7d8665.jpg.html)

Then the Mequiars plastic polish.....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0092_zps66afb682.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0092_zps66afb682.jpg.html)

And now your done.  Here is the redone lens next to a spare.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0107_zps3534732c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0107_zps3534732c.jpg.html)

And then I cut out a new gasket from some foam rubber neoprene.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0095_zpsce970dc1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0095_zpsce970dc1.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 21, 2014, 10:28:31 PM
I did a bunch of research, and it appears that my Isspro Tach will work with the factory wiring under the dash.  The only problem was with the light housing.  With the tach in the column mounted housing it would only go in 75% of the way...the big light housing on the back of the tach was hitting.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0012_zpse44cf9e4.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0012_zpse44cf9e4.jpg.html)

I first thought I would have to buy a new tach.  But after some more on-line searching I found a solution to my problem...remove the light housing!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0013_zpsc15d399a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0013_zpsc15d399a.jpg.html)

Now I had to figure out some new lighting.  I went with a couple bullet LED's.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0014_zps0e0b3a76.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0014_zps0e0b3a76.jpg.html)

I cut a piece of rubber, and then made some slits in the back and pushed the LED's through.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0016_zpsaddad909.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0016_zpsaddad909.jpg.html)

Then I glued the rubber in place.  Not super bright....but works good enough for me.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0018_zps20d1be94.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0018_zps20d1be94.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 21, 2014, 10:41:07 PM
I installed the firewall insulation from the donor 93.  It was originally glued to the firewall.  Took me a long time to carefully get it out when I tore the 93 down.  But I was able to get it installed, and secured in place with no glue this time.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0004_zps2998e764.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0004_zps2998e764.jpg.html)

Once that was done I installed new shaft bushings on the clutch and brake pedals.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0034_zpsb838f6cb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0034_zpsb838f6cb.jpg.html)

Then it was heater/AC box, power window and door lock wiring, and the vents.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0055_zpscaf40e4c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0055_zpscaf40e4c.jpg.html)

Now it was time to wrestle that dash back into place.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0057_zps8d9b0e40.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0057_zps8d9b0e40.jpg.html)

Went in relatively easy.  Only thing I did was to add some slightly larger washers under all the 5/16" head screws.  So that it would grab the holes in the dash without breaking them....a very common problem.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0058_zpscc28dea1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0058_zpscc28dea1.jpg.html)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 21, 2014, 10:47:54 PM
And I was going to use the original clutch rod boot...which I did manage to find in my parts stash....but decided to another route.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0002_zpse0d5e7c3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0002_zpse0d5e7c3.jpg.html)

You can see in the pic that I left the delete plate in place, but drilled a hole in it and put in a wiring grommet.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0050_zps4979fbe6.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0050_zps4979fbe6.jpg.html)

I also installed longer screws....long enough to poke through the firewall insulation.  Then I found a couple small washers, and some old pal nuts, and installed those to help hold things in place.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0007_zps0df61c51.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0007_zps0df61c51.jpg.html)

Now when I feed the wiring through it will tuck up and behind the firewall insulation and then to where I want it to run.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 21, 2014, 10:58:10 PM
Went to install the rad support, but discovered that two of the bolts that I used to replace the rivets were going to be too high and hit the underside of the rad support.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0098_zps74a13a6d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0098_zps74a13a6d.jpg.html)

So I went down to a local industrial supply shop and we were able to find a couple 1/2", fine thread, button head bolts, in Grade 8 too boot!!  Worked perfect!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0097_zpsca764620.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0097_zpsca764620.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0099_zps19133aee.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0099_zps19133aee.jpg.html)

Then installed the inner fenders. Starting to look more and more like a complete truck.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0100_zps34329b90.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0100_zps34329b90.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 21, 2014, 11:22:09 PM
Installed the front fender one day.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0005_zpsb32888ed.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0005_zpsb32888ed.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0007_zps0d33e059.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0007_zps0d33e059.jpg.html)

Then a few days later got the hood and lower grille support panel in.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0015_zps618917b2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0015_zps618917b2.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0017_zps02420c3d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0017_zps02420c3d.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 21, 2014, 11:24:27 PM
Had to modify the lower grille panel a bit to clear the PS IC.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0019_zps90417cd5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0019_zps90417cd5.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0020_zpsf477c9bb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0020_zpsf477c9bb.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0022_zps152384a6.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0022_zps152384a6.jpg.html)

Hope the grille will clear the IC with no modification.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 21, 2014, 11:30:04 PM
I then had to spend a couple hours carefully modifying the hood catch.  I had to cut out about 3/4" I guess.  But through it all I had to carefully alter things to clear.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0024_zps327c4c3e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0024_zps327c4c3e.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0023_zps78fa09e1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0023_zps78fa09e1.jpg.html)

I also filed down the tabs at the back.  This allowed the hook to roll inwards a bit more towards the rad support, and give it a little extra help in clearing.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/MArch%202014/PICT0026_zps6e9d85c4.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/MArch%202014/PICT0026_zps6e9d85c4.jpg.html)

I would be more specific on what I did...but this all depends on how you go about installing your PS IC.  Some people have not had to alter the hood catch, many do have to alter theirs.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 21, 2014, 11:31:54 PM
It's late...I'm done updating for tonight.  Maybe one more evening i will be caught up.  That is if I don't get a bunch more stuff done in the mean time....;)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on March 22, 2014, 07:45:44 AM
Yep, looking like a real truck again. Great job and thanks for posting pictures!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 22, 2014, 09:44:21 AM
Thanks!!  Yeah it's starting to come together now. 

Was hoping to be driving it by now, but these little projects keep eating up more and more time.  But better to do it "right" now then to have to dive back into it later and fix all those "little" things.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 22, 2014, 04:54:12 PM
Thanks Brian.  Wish I could get you in there with me.  We need some talent.

http://igotacummins.com/showthread.php?2590-How-to-Refurbish-convert-upgrade-a-1st-Gen-Dodge-Ram&p=27023#post27023 (http://igotacummins.com/showthread.php?2590-How-to-Refurbish-convert-upgrade-a-1st-Gen-Dodge-Ram&p=27023#post27023)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 23, 2014, 08:07:00 PM
Quote from: POLARACO
Thanks Brian.  Wish I could get you in there with me.  We need some talent.

http://igotacummins.com/showthread.php?2590-How-to-Refurbish-convert-upgrade-a-1st-Gen-Dodge-Ram&p=27023#post27023 (http://igotacummins.com/showthread.php?2590-How-to-Refurbish-convert-upgrade-a-1st-Gen-Dodge-Ram&p=27023#post27023)


I joined up Steve.   Not much activity in the 1st Gen sections though.  I will stop in from time to time and see if I can help out.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 23, 2014, 08:59:45 PM
U da man
I saw that.  It's really a good group of gals and guys alike.  It's a civilized forum with some real good talent.  Not much guessing goes on.  If we do guess, we say so.  But most of their guess's are pretty close.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 11, 2014, 09:42:25 PM
OK time to start catching up on the updates.  Will try and get caught up in the next day or two.

OK after I got the roof panels in I needed wanted to install some additional dome lights.  Since the dash map light, and the rear dome light above the rear window would not be bright enough.  I already had a hole in the passenger side  interior A-pillar from a CB radio antenna.  So I drilled another corresponding hole on the drivers side.  

I then searched and searched on-line looking for the "right" unit to use as additional dome light.  I ended up buying some front marker lights for a 53 Chevy...but they were way to big.  Then I was digging through some of my full size Chrysler parts and came across a set of courtesy lights from a 66/67 Chrysler.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0002_zpsdee7c5e4.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0002_zpsdee7c5e4.jpg.html)

These were the ones I was looking for.  Unfortunately the lenses were yellowing and cracked.  But after some digging I found new reproduction lenses!!

Then I bought some small 1" x 1.25" Super bright LED panels to go inside.  They are for dome light retrofit, so they come with 3 additional connections.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0003_zpsa7884a54.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0003_zpsa7884a54.jpg.html)

I then had to figure out hoe I was going to mount them.  I ended up marking, and cutting out some gaskets from my neoprene rubber material.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0004_zps039682fd.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0004_zps039682fd.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0005_zpsd5dd3ca5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0005_zpsd5dd3ca5.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0006_zpsf012b951.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0006_zpsf012b951.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 11, 2014, 09:47:15 PM
Then I had to figure out how I was going to mount the LED panels within the light housings.  I ended up making a couple sheet metal plates that would go between the gasket, and the lens.  Then I could mount the LED panels and run the wiring back into the hole.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0022_zps4a57488d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0022_zps4a57488d.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0023_zps301f54e4.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0023_zps301f54e4.jpg.html)

And installed.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0025_zpsf063c282.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0025_zpsf063c282.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0024_zpse9864bec.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0024_zpse9864bec.jpg.html)

Man is it bright in the cab now at night.  Almost like day time when you pop the door open!


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 11, 2014, 09:51:56 PM
Sorry I didn't always take a lot of pics while I was working.  But did snap a few here and there.

I went to install the steering column.  I needed a new column gasket.  I made my own out of the neoprene foam gasket material.  I cut out two gaskets...mirror images of each other and then installed.  Worked great!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0012_zpsbdc4c4df.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0012_zpsbdc4c4df.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 11, 2014, 09:57:53 PM
Since I'm running the 2nd Gen rims I needed to modify a couple caps to go over the front 4wd hubs.  I didn't want to cut up a dodge ram logo head cap, so I bought a pair of generic aftermarket units.  

I heated up an old hacksaw blade with a torch, and slowly melted my way around the 5" hole I marked out.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0011_zps172f6a46.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0011_zps172f6a46.jpg.html)

Then I used a flapper disc on my air rotary tool to clean up the edges, and open the hole up a bit more.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0010_zps77d0738f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0010_zps77d0738f.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0009_zpsca9855ad.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0009_zpsca9855ad.jpg.html)

They are a little tough to get off the front rims...but look good.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 11, 2014, 10:05:08 PM
I then got the rear plastic trim installed around the back window.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0051_zpsed1b4e61.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0051_zpsed1b4e61.jpg.html)

Then I could install the rear carpet that mounted on the back wall of the cab.  But I first added a bit if the mighty mat.  Used some thin, super adhesive two sided carpet tape to hold the mighty mat to the back side of the carpet.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0054_zps99a8442a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0054_zps99a8442a.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0055_zpsb3574ba6.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0055_zpsb3574ba6.jpg.html)

And installed.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0059_zps80eb1a78.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0059_zps80eb1a78.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 11, 2014, 10:09:12 PM
Then came the insulation and carpet.

I used some rubber mat on the very bottom.  Then the mighty mat on top.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0060_zpsf44f1fb2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0060_zpsf44f1fb2.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0058_zps86ce0e38.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0058_zps86ce0e38.jpg.html)

Then came the carpet.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0061_zpsa2a7a15f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0061_zpsa2a7a15f.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0062_zpsf2dfadb0.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0062_zpsf2dfadb0.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 11, 2014, 10:10:49 PM
That's it for tonight...more to come. ;)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 08:10:30 AM
I wanted to install my new brake controller...it's a prodigy controller BTW...;)  And didn't want to drill holes in the dash...so I was looking for a way to mount it in the least intrusive way.  I finally decided to use my ash tray cover as the mounting point.

Here's what I did....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0038_zps61097f3d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0038_zps61097f3d.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0039_zpsc1f73d13.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0039_zpsc1f73d13.jpg.html)

Then mark and drill the holes...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0040_zps80dd554c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0040_zps80dd554c.jpg.html)

Couple long screws, and washers and nuts and it was done....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0041_zpsf5524eb5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0041_zpsf5524eb5.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0042_zps253e221b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0042_zps253e221b.jpg.html)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 08:14:44 AM
The donor doors were missing the covers that go over the speakers.  Luckily I had a set I grab out of the junk yard a number of years ago.  

So i needed new gaskets to seat against the door, and the speakers. Again I went back to my neoprene foam gasket material.  Cut a bunch of long thin strips and attached them.  The neoprene material i got has one side with adhesive on it it, so you can peel and stick where needed.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0070_zps83274b1e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0070_zps83274b1e.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0071_zps8c3ad1d1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0071_zps8c3ad1d1.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0069_zps5696cd78.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0069_zps5696cd78.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 08:21:12 AM
I decided I didn't want my boost, and EGT gauges on the dash.  So I painted up a spare LH pillar post cover grey.  Then went about installing an Autometer 2 pod cover.

I didn't like the way the instructions said to install it.  So I decided to make my own version.  I ended up cutting some small pieces of sheet metal.  Then I bent them to the contours of the back side of the trim.  Drilled holes and mounted the sheet metal, along with a generous amount of Marine Goop.  Let that dry for a couple days and voila!!  A removable 2 pod  trim!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0037_zps8eeadb2f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0037_zps8eeadb2f.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0036_zpsacf92163.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0036_zpsacf92163.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0035_zpsb85a91cb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0035_zpsb85a91cb.jpg.html)

So now I can install the pillar cover.  Instal the gauges and wiring, then screw them in place.  Only issue now though is that the screws by the windshield, and lower corner of the dash are a bit tight to get to, and tighten up.  But the use of a short 90* phillips head wrench worked fine.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 08:26:59 AM
Now it was time for the shifter.  I had picked up this shifter nearly 20 years ago.  It was done as a barter trade for a 6 way manual adjustable seat track I had for a 69/70 B-body.  The guy I traded with made these shifters out of stainless steel, and with custom hand made wood grips.

So here it is.....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0067_zps387b0161.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0067_zps387b0161.jpg.html)

It's a 70 B-body (roadrunner, charger, coronet) pistol grip style shifter.

To get things to work, I had to drill an additional hole in the shifter, and then the corresponding hole in the old shift tower stub.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0026_zpsbb0caadf.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0026_zpsbb0caadf.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0027_zpsd540c1a1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0027_zpsd540c1a1.jpg.html)

I had been looking for a vehicle to use this in for many years, and since after the redo on the truck I figured this would be the perfect place to use it.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 08:36:27 AM
I cleaned up the doors...front and rear.  Installed all new seals and window sweeps.  Only issue I had with this was with the supplier of the window sweeps.

They supplier was Fairfield I believe.  Well they decided to cheap out and replaced the clips that slide into the door to hold them in place with plain metal clips...not the spring steel that they should be.  Well you can guess what happened.  The darn sweeps would not stay in place., since the clips would bend, and stay bent, when you installed them.  

So I fought that for a coupe days.  Had to carefully remove the clips from the old sweeps and install them on the new ones.  Huge hassle!![verymad]

So if you are considering getting sweeps....stay away form the ones manufactured by Fairfield..  The ones I got from JCW years ago were fine.  Those actually came out of Mexico.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 08:38:07 AM
So that's about it.  Truck is basically done!!  

Installed a good set of saddle blanket grey seat covers, front and rear and called the interior finished.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0079_zpse4dbe305.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0079_zpse4dbe305.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0080_zps530c84ce.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0080_zps530c84ce.jpg.html)

Rear door panels got cleaned, and repainted.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0081_zpsaea2cc2e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0081_zpsaea2cc2e.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 08:45:46 AM
And here it is ready to go....My daughters have dubbed the crewcab "Patches"....[laugh]  They don't want me to paint it....they love it the way it is.:cool:

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0077_zps53eefe5b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0077_zps53eefe5b.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0075_zpsb84cab71.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0075_zpsb84cab71.jpg.html)

I started driving it the first week of May.  Have put on about 1300km's so far.  I will go into the few issues I have had to deal with later.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on June 12, 2014, 09:54:26 AM
Looks good, and works for me. A fine job and thanks for all the pictures, makes it a lot easier to follow what you did.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 07:16:35 PM
Quote from: dana44
Looks good, and works for me. A fine job and thanks for all the pictures, makes it a lot easier to follow what you did.

Thanks.  I try to make it as informative as I can. (http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 07:16:50 PM
I knew I forgot a couple things.....[laugh]

There was the seat belts.  I had the complete set from the clubcab donor truck...in grey.  And I lucked out and got a complete grey set from the wrecker from a regular cab truck.  

So I cleaned everything up really well.  Lots of simple green and a scrub brush to clean all the webbing.  If you haven't scrubbed your belts...I highly recommend it.  They are nasty things!!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0036_zpsfb746468.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0036_zpsfb746468.jpg.html)

I also didn't like the broken, and sharp plastic sleeves over the belts.  So i cut them off as well.

Cleaned up and set out to hang dry.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0043_zpsebca67ac.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0043_zpsebca67ac.jpg.html)

Wonder what the neighbors thoought of my redneck wind chimes.....LOL...


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 07:22:12 PM
Only thing I had to modify was for the rear seat lap belts.  The auto winder ones.  

Here is a pic of the original crewcab unit in red, and the rear clubcab unit in grey.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0051_zps9dd13806.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0051_zps9dd13806.jpg.html)

What I wanted was to use the clubcab unit, but the buckle would not work.  Seems Ma. Mopar decided to use a different buckle and latch set up for the rear seat belts in the clubcab.  

So I decided I would remove the sticking on the grey belts...to get the buckle off cleanly.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0053_zps44301274.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0053_zps44301274.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0054_zps906eed1c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0054_zps906eed1c.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0055_zps3dd01b40.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0055_zps3dd01b40.jpg.html)

Took a while to work out the old stitching...but eventually got it all out.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 07:26:21 PM
Then it was cut the buckle off the red belt, and have the upholstery shop sew them back up.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0056_zpseab16bb5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0056_zpseab16bb5.jpg.html)

Here you can see the difference in the two buckles....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0057_zps9fa24e97.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0057_zps9fa24e97.jpg.html)

Ready to get sewn up....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0058_zpsf7351cdc.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0058_zpsf7351cdc.jpg.html)

The shop did it for free, since I had already done all the hard work.  Took like 2 minutes on their machine. ;)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 07:38:35 PM
Man another thing I forgot....(http://www.moparfins.com/forum/smileys/smiley5.gif)  The PS IC tube install.  

I had wanted to try and re-use the OEM intercooler tubes.  The only issue I had with the OEM tubes was that corrosion had got under the powder coating. [SIZE="1"](This is why I don't like powder coating)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0104_zps41f45789.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0104_zps41f45789.jpg.html)

Wire wheeled them clean....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0001_zps149465c4.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0001_zps149465c4.jpg.html)

And then painted them gloss black....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0027_zps584c07e7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0027_zps584c07e7.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 07:46:03 PM
I had taken measurements when the OEM intercooler was in place, then after I installed the Power stroke intercooler.  And had figured I needed a few parts from Silicone intakes.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT8655_zpseaa61b3b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT8655_zpseaa61b3b.jpg.html)

And this is what it looked like when I trial fitted things.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0032_zpsd430faa6.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0032_zpsd430faa6.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0031_zps280a9458.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0031_zps280a9458.jpg.html)

A little closer then I had planned on.  Turned out the OEM boot was about 5" , and I needed a 3" boot.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 07:58:56 PM
So I looked at some aftermarket "Humped" boots...but they were pretty weak in the humped area. [laugh]

So I decided to use the OEM boots.  Just required a little trimming.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0030_zpsd006a9a9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0030_zpsd006a9a9.jpg.html)

Careful measurements, and even more careful cutting with an exacto knife, netted me a boot that would work perfectly.

All button up....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0034_zps40ec8f0f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0034_zps40ec8f0f.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0033_zps08ff4857.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0033_zps08ff4857.jpg.html)

I really like the Silicone intakes website.  They have every measurement you could possibly need on their items.  Makes it very easy to get the right part the first time.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 08:09:54 PM
So the first issue I had was with the fan lightly hitting my Fluidampr.  I had shimmed out the clutch fan away from the hub by a good 1/4"...but one blade was still touching every so often.  

The light "Ting ting ting" sound would come at higher RPM's...1800+.  I eventually had to pull the fan and remove a bit of material from the one fan blade.  Since then i have not had an issue.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 08:20:07 PM
Next issue was the total lack of power the motor seemed to have.  It would barely climb up a hill at 35 KM/H in 3rd gear.  It was bad!!  I thought I had some major issues.

I initially thought I had a 21cm2 exhaust housing, but I confirmed that it had a 18cm2 unit.  OK so that was not my problem.  

Next I thought maybe the OEM diaphragm lift pump was not supplying the motor with enough fuel.  So I pulled the LP piston lift pump off my 89 motor and installed it on the 93.  This did help a little....I was now up to 40-45 KM/h going up the same hill.

Then I noticed while cruising at a steady speed that once in a while the motor sound would change.  I got thinking about it and thought that maybe the KSB was coming on while driving.  I came to the DTR and did a ton of reading on KSB's.  

I finally found a test procedure and tried that.  Turned out the KSB was on all the time.  My intake temp sensor is toast.  And once I disconnected the wiring to the KSB the truck was like night and day.

I also need to mention that I had installed a M&H dynamic timing spacer when I resealed the IP.  So with the KSB on all the time I was running probably 15-20* more timing.....Doooh!!

 

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 08:31:52 PM
Then a week or so ago I started to get a really bad growl, shake when i got on the highway.  Thought maybe the pinion bear was starting to go since it was worse under load/acceleration.

Did a quick check and found that the rear most weld on yoke had opened up and I had a fair amount of side to side play in the U-joint.  I used a C-clamp to tighten things up, then installed a washer to take up the extra space.  Also turned out that the slip yoke off the back side of the carrier bearing had one U-joint cup that was loose and spinning in the casting.  

I had to get back and forth to work for a couple more days before I could get the drive shafts out and back to the shop that did them.  So the washer was a temp fix, and I kept off the highway and stayed below 65 KM/H.

The driveline shop that RE/RE'd my original 2 pieces set-up had said everything was good.  And they only replaced two of the wled on yokes the first time around.  Well now the parts that they said were OK turned out to be shot.

I have had issue with this shop before.  The owner will not stand behind his work.  But the other shop I had been using got out of car/truck drivelines, and this shop was the only one relatively close by.  So once again he weaseled out of proper customer service and I got stuck with another full bill to fix what they didn't do right the first time.[verymad]

I have since found another shop.  They don't advertise, so you have to know someone one who knows.  So I will be going there next time.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 12, 2014, 08:40:27 PM
The last issue I have right now is with the factory electronic cruise control system  What my truck is doing is that when you set the cruise, it will sit at the set speed for a second or so...then start speeding up.

I have read every thread I could find here on the DTR, and other sites, that pertain to the factory cruise set up.  I have also done every test that the FSM (factory service manual) says to do to test the system.  Everything checks out.  It should, in theory, be working perfectly.

I have come to the conclusion though that perhaps the "Vent" function is the culprit.  Since the ECM is supposed to control the "venting" function on the servo to help maintain the speed, as well as increase, and slow down as need by road conditions.

So the other day I thought maybe if I limited the amount of vacuum to the servo it might help.  I reduced the ID of the vacuum line down to about 1/16th of an inch and it still persisted in doing the same thing.

So now I need to figure out how the vent system works on the servo.  And/or find a servo from a working truck/car and try it on the crewcab.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on June 13, 2014, 08:42:05 AM
I have a headach
Use the gasoline procedures on the cruise
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 20, 2014, 04:16:44 PM
Quote from: POLARACO
I have a headach

OK I'll try that Steve...I'm at a loss so I'll try anything....Thanks!



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 20, 2014, 04:16:51 PM
Well I was under the truck again the other night...and guess what...the rear most weld on yoke is spreading AGAIN!![verymad]  Not as bad as before, but I can still wiggle the U-joint back and forth about 1/32" to 1/16".

I also discovered the b@st@rds did not put any grease on my front drive shaft...in the splined slip joint.  And the rear slip joint off the carrier bearing had just a small dollop.  

My guess is they re-used one, or both of the universals that were compromised in the last cr@ppy job they did.  And then charged me for "new" parts.

I greased up all the joints again and went for another drive.  Slightly better, but still growling the worst on the decel.

I'm going over to my brothers next week to have him check out the rear diff.  He worked in a drive line shop for a couple years just doing diffs and transfer cases.  So this should tell me if my rear axle has anything to do with the noises and vibrations.  

My gut is telling me it's those friggin driveshafts!!

I'll be going to their shop next week to ream the owner a new one, and inform him I'm placing a negative report with the BBB, and will be letting all my on-line forums, and friends by word of mouth, know about his shoddy customer service and craftsmanship.


thrashingcows2014-06-21 02:20:23
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on June 20, 2014, 04:27:10 PM
Good for you. I will be sure not to use them.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on June 20, 2014, 05:57:04 PM
Unfortunately there's allot of that going on.

Send your brother down here.  He can finish my diff on my truck for me.  That's a whole different story
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 20, 2014, 09:18:36 PM
I got the air intake sensor sorted out today.  I went up to my local parts house and we cross referenced the SMP AX36 with the brand they carry.  They carry BWD, so the cross references is WT3032.

We looked up a picture in the catalog and it appeared to be correct. It also only listed it for 94-98 Dodge rams, no reference to 91-93.  Anyway they brought it in for me and it was the right piece.

We looked through teh catalog and found a picture of a sensor that matched the one I received.  It appears to be an air temperature sensor for A/C systems on mopars from late 80's to late 90's?

Anyway here is a pic of the 3 sensors.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202014/PICT0147_zps7754782d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202014/PICT0147_zps7754782d.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 27, 2014, 08:39:08 AM
The other day I went back out to the drive line shop, to talk to the owner about mu continuing issue with the driveshafts.  Man is that guy a friggin A-Hole!!

In not so many words, and in a round about, back handed way, he called me a whiner and a liar, and accused me of not knowing what I'm doing, and that possibly "I" was damaging the driveshafts.

I will "NEVER" be going back to this guy.  I won't bad mouth him on-line...since he reluctantly said he would warranty the pieces.  But this will be the last and final time dealing with him and his shop.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on June 27, 2014, 08:47:31 AM
On a slightly better note...We had a nice family BBQ last night, and then my brother and I tore into my rear diff.

Well it's not all good news for the Dana 70.  The power-loc unit is worn out, and the pinion is running deep on the ring gear.  Enough to run past the outside edge of the gear.  And it appears I have at least one wheel bearing that is a bit iffy.  

But my brother says there is nothing that can't wait a few weeks, or longer, to address.  So now I have to source all new parts for a complete diff rebuild.  Thankfully my brother has all the tools required to do it in his shop.   So it will be a learning experience for me as well.

On a bit of a funny note...while talking with my brother last night I was telling him my issues with my driveshafts.  He finally asked who was doing the work...so I told him...he laughed and told be he had worked for this guy a couple years ago.  And that he is truly an A-hole to work for as well.  he said he only lasted a few months and had to get out of there.
 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on June 27, 2014, 12:22:37 PM
Well at least you can now confirn it isn't you! Good luck with the diff. They aren't hard jobs, but you have to know a couple little secrets to get them right, sounds like your brother knows them.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on June 27, 2014, 05:28:25 PM


To refresh your memory, I upgraded from 373's to 342's.  Dropped my RPM 200 and gained 2 MPG.  I just took a trip with it.  I did 550 miles on less than 3/4's of a tank.  That puts me on the 25 to 26  MPG range now



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 01, 2014, 01:18:21 PM
Wow Steve...That is an amazing change for just a slight gear drop!!(http://www.moparfins.com/forum/smileys/smiley32.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 09, 2014, 10:25:45 PM
Last week I decided to tackle the oil cooler.  I had been seeing a bit of coolant leaking from my oil cooler. So bought new gaskets from cummins, and went at it.

The bolts holding the oil cooler should be at 18ft/lbs...mine were maybe 5ft/lbs when I removed them!  I would recommend that you check your oil cooler bolts.

Once I got the assembly out of the block, I ended up with a couple loose pieces.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202014/PICT0157_zpsa2dcfd05.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202014/PICT0157_zpsa2dcfd05.jpg.html)

That is the pressure relief valve for the oil bypass.  It is supposed to be one piece!  

And this is where I found the top piece of the relief valve.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202014/PICT0162_zps587626f3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202014/PICT0162_zps587626f3.jpg.html)

So I spent the next couple hours trying to find one.  No one seemed to have one, and the cummins dealers parts department was closed, due to the long weekend.

I eventually called a friend who said he had a complete unit I could try.  So i buzzed over there and grabbed it.  Turned out the pressure relief valve in this one was shot too!!  I just couldn't get a break. :(

So I went back and cleaned up the gasket surfaces.  What a PITA.  Not sure what those gaskets were held on with, but it took wire wheel, and small sanding discs to get it all cleaned up.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202014/PICT0156_zps8ccf74da.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202014/PICT0156_zps8ccf74da.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 09, 2014, 10:33:44 PM
So since I needed the truck to go to work the next day, I decided it was time for some back yard engineering. ;)

I hunted around the garage trying to think of what I could use to assemble, and secure the relief valve so it would function as a single piece again.  I dug through many of my containers of MISC.  Stuff I see, find and have left over from projects and such that I toss in containers because " I might be able to use that one day...."

Well eventually I came across this...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202014/PICT0161_zpsc39ad298.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202014/PICT0161_zpsc39ad298.jpg.html)

Think it was leftover from some Ikea furniture?  Anyway I carefully removed the rolled metal around the middle.  The ground off one end so i could get to the spring star washers.  Then I slowly, and carefully bent and ground down the fingers until I was able to sneak it into the bore to hold the relief valve back together.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202014/PICT0158_zps5937a1f7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202014/PICT0158_zps5937a1f7.jpg.html)

Worked really well, super snug and biting hard into the aluminum.  I was able to get things back together and have not had any issue so far.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 09, 2014, 10:40:24 PM
I also spent a little time working on quieting up the 4wd shift lever.  I was rattling quite a bit.  Here is a the piece that came in my Advance adapters NV4500 to NP205 kit, Vs the OEM unit.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202014/PICT0148_zps7194c207.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202014/PICT0148_zps7194c207.jpg.html)

I needed the end that be tighter on the transfer case.  So I used some rubber and worked it in between the clevis and shift bar.  It was tight, and took some time to get everything in place and lined up.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202014/PICT0149_zps34622c52.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202014/PICT0149_zps34622c52.jpg.html)

The other end just required the addition of a small spring washer to take up the little bit of slop.  Nice a quiet now!!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 09, 2014, 10:46:47 PM
And I cut up my original "Power Ram 250" emblems so I could make my "Power Ram 350" emblems.

I used my table saw to carefully cut the "power" portion of the original emblem off.  Then I had to sand down the piece to fit tight against the "RAM".  The "A" sticks up just a little bit.  Once fitted I put a couple coats of paint on the lower section that was cut and sanded.  Then one dry some two sided tape and installed everything.

Think it turned out good.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202014/PICT0151_zpsdf668e9c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202014/PICT0151_zpsdf668e9c.jpg.html)

After how much the last set I saw on e-bay go for...think it was around $300?  This works just fine for me.... ;)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Bill Mounteer on July 10, 2014, 11:21:08 AM
Wow Brian, what an amazing job you've done!  I started at page 1 and here I am over two hours later, a great write-up with lots of pictures. The before and after interior shots make it hard to believe it's the same truck, very well done! I had to chuckle at a few of the pictures, doesn't it ever stop raining in Abbotsford! LOL

 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 10, 2014, 05:29:12 PM
Hey Bill...Good to hear from you.  Thanks for the kind words.  It's been a lot of work, but I really have fallen in love with these cummins powered trucks. 

Post up some pics of your car.  Would love to see where it's at now.  Find any more 440 powered Fury III 'verts?


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on July 10, 2014, 10:00:43 PM
Good job McGiever
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 11, 2014, 08:20:49 PM
Quote from: POLARACO
Good job McGiever

Thanks Steve.!  We sometimes have to think outside the box, so we can get back on the road. (http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 11, 2014, 08:20:57 PM
Thanks everyone!

Well yesterday I figured it was time to get the AC working.  

I had cleaned the evaporator, lines and condenser when I had everything apart.  I installed a new AC compressor, it was pre-filled with about 5oz of oil.  I then read through the FSM ad found that I needed to add another 4oz.  So that went in and I then installed a new drier.  Closed everything up and ran a vacuum on the system for 30 minutes.

I then installed the 134a conversion fittings, and refilled it with Duracool.  The operating line pressures are within proper spec, but I just am not getting the cool temps I should be seeing.  Even on the Hwy I am only getting moderately cool air from the vents.

I think this has a lot to do with the AC condenser being behind the Power Stroke Intercooler.  It's just not getting the cool air "first" like it needs to properly transfer the heat.

I'm going to install a couple manual shut off valves on the heater hoses to stop ALL the coolant from entering the heater box.  Just so you know, even with the vacuum controlled valve on the inlet heater hose to the heater core...you still get parasitic heat drawn into the heater core from the outlet line.  Hope this helps a little.

If I can't get the AC temps down where they should be, or where I can live with them, then next spring I'm going to install a remote condenser with fans under the box.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Bill Mounteer on July 11, 2014, 09:01:26 PM
Quote from: thrashingcows
Hey Bill...Good to hear from you.  Thanks for the kind words.  It's been a lot of work, but I really have fallen in love with these cummins powered trucks. 

Post up some pics of your car.  Would love to see where it's at now.  Find any more 440 powered Fury III 'verts?




Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on July 11, 2014, 09:47:34 PM
Hi Bill



No way you can flip the condensor and Intercooler hih?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on July 11, 2014, 10:00:14 PM
Brian

http://igotacummins.com/showthread.php?2921-Calling-all-Canucks&p=30675#post30675 (http://igotacummins.com/showthread.php?2921-Calling-all-Canucks&p=30675#post30675)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on July 12, 2014, 09:09:52 AM
A heater core shutoff valve should help. I know that if there is heater core water flowing through the cabin core you are simply cooling hot air, and I have always had some kind of heater hose shutoff valve in all my AC cars.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 12, 2014, 10:20:11 AM
Quote from: POLARACO
Brian

http://igotacummins.com/showthread.php?2921-Calling-all-Canucks&p=30675#post30675 (http://igotacummins.com/showthread.php?2921-Calling-all-Canucks&p=30675#post30675)



Thanks Steve....but I had an OEM intercooler from my donor truck.  I went with the BIGGER Power Stroke IC because I only use the AC for a few weeks out of the year.  The motor can benefit from cooler EGT's year round. (http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on July 12, 2014, 03:19:44 PM
OK  I'll delete that.  I thought it would be fun to rattle a couple of the Canadian Cages.  LOL
You have room to fit an electric fan behind the grill?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 12, 2014, 03:33:13 PM
There's barely enough room to get the grille in place without hitting the bigger PS IC.....(http://www.moparfins.com/forum/smileys/smiley5.gif)  In fact it almost touches in a couple places.  I had to add a little foam tape to a couple area to keep the grille from potentially hitting the IC.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 12, 2014, 08:22:24 PM
Playing with the AC again this after noon...100+*F today, and humid as heck!!

Anyway the AC charge was low...turned out the cap on the retrofit adapter valves was a tad too long and it was hitting the schrader valve just enough to allow it to slowly bleed off....DoooHHH!

So got that figured out, then charged it back up.  Still only getting tepid air out of the vents.  Was checking the Heater hose shut off valve, and it seemed to be working properly, but I thought I may as well just remove it and double check.  Well it wasn't stopping any coolant flow.  It would move properly, and appeared to be functioning, but whatever was inside the valve to shut down the flow of coolant was rotted, or missing.  I had another valve...but it was the same.  So the coolant lines got disconnected and looped together.

So we will see if the AC works a bit better now that I don't have steaming hot coolant entering the cab.[redface]

So those who are having cooling issues with your AC...try checking this valve first.  Even if it "appears" to be working, it very well might be non functional inside.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on July 13, 2014, 08:43:12 AM
Like I said, flow some cold water over the condenser and then check the temp.  That will tell you allot.   
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 13, 2014, 09:52:35 AM
Quote from: POLARACO
Like I said, flow some cold water over the condenser and then check the temp.  That will tell you allot.   

Right...forgot about that advice....(http://www.moparfins.com/forum/smileys/smiley5.gif)....(http://www.moparfins.com/forum/smileys/smiley36.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on July 13, 2014, 12:05:07 PM
How's the AC when you are driving it at low and high speeds?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 13, 2014, 06:44:32 PM
Went for a bit of a drive today...110*F out there today!  I was getting cold air, but I think the cab of the truck only got down to around maybe 72-75*F?  It was comfortable, but not cool in there. 

I was concerned a couple times because I heard this roaring sound.  Turns out my fan clutch is working just fine...it's locking up into "Severe Duty" and pulling a ton of air.





Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on July 15, 2014, 06:51:18 PM
Went for a drive up to a lake with my daughters today to go swimming.  Dirt road in and out from the lake.  Lots of noises coming from the truck.  Thought for sure the front end was coming apart.....:(.....:)

So after dinner I crawled around checking everything, making sure nothing was coming loose etc.  Well my battery hold down had worked it's self loose, and the battery was close to falling down in behind the tray.  Also one of the bolts holding the end link in place on the front sway bar was missing....the other one was finger tight.  So these got fixed this evening.

Some of the Noises that I could identify are coming from the front outer brake pads...loose and jiggling against the calipers.  The skid plate is rattling against the tranny mount.  The air cleaner assembly is making noises in it's OEM bracket.  These will get fixed this weekend.

But other then that it was a nice day out with the kids.

Here are a couple pics....forgot my good camera, had to use my phone.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202014/IMG-20140715-00153_zps355b8317.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202014/IMG-20140715-00153_zps355b8317.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202014/IMG-20140715-00162_zpsb6a304c5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202014/IMG-20140715-00162_zpsb6a304c5.jpg.html)

 
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 29, 2014, 05:23:36 PM
OK I decided to try and be lazy....I ordered one of those H4 headlight relay kits off E-bay. Wondered about the quality of these kits so I paid $15 shipped....so not out too much.  ;)

Here are a couple pics of the kit I ordered....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/August%202014/PICT0234_zpsf2c6cef2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/August%202014/PICT0234_zpsf2c6cef2.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/August%202014/PICT0233_zps2f8b0fe5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/August%202014/PICT0233_zps2f8b0fe5.jpg.html)

Well decided to install it quickly and see what happened.  My 93 donor was a Canadian truck, so it came with the daytime running lights...which still work properly.  So I hooked up the system with the primary hook up on the passenger side, since that is where the main power for the DRL come from.

The high and low beams seemed to work fine.  But when I shut off the lights, and then moved the truck to get the DRL to come on..(Yup it needs to sense movement or they will to come on).  The relays in the system were buzzing like crazy, and only the drivers side would light up.  The passenger side was very, very dim...just a slight glow in the bulb.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 29, 2014, 05:24:13 PM
So guess it's a no go.  But what really got me was that I was feeling the wires, and even though they looked like 10/12ga...they were really soft.  So I decided, since I was not going to be using the kit, to open up the main power wire.  Wow what a deception they have going on there!

Here is a 10/12 gauge piece of wire on teh left, and the "10/12ga" wire from the kit on the right.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/August%202014/PICT0236_zps3d843b6d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/August%202014/PICT0236_zps3d843b6d.jpg.html)

I actually measured the wire strand and if it's 18ga I think you'd be lucky.  All coating on the wire to make it look bigger then it really is.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 29, 2014, 06:30:16 PM
Brian



The system may be pricey, but the rewards are well worth it.  You'll see that moose 1/2 a mile away.  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 30, 2014, 09:43:37 AM
Quote from: POLARACO
Brian




No not really Steve.  I'm quite happy with my stock halogen bulbs.  I want to take the load off the headlight switch...that's about it.  If I get a little better lighting from the conversion, well that's just a bonus, not a necessity. ;)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: R. Dave Carr on August 30, 2014, 10:00:36 AM
I have personal experience with several sets of these, much lower current drain, and much improved visibility at night.  These are the future of lighting.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 30, 2014, 11:18:43 AM
Quote from: carrman
http://www.truck-lite.com/webapp/wcs/stores/servlet/ProductDisplay?storeId=10001&productId=92027


I have personal experience with several sets of these, much lower current drain, and much improved visibility at night.  These are the future of lighting.

I have seen a few pics of 1st Gen's with these headlights...have to say I am not impressed with the look when the lights are on.  I have driven some of the new commercial trucks that have LED's...again not impressed.

The LED's do seem to give you a better low beam light.  But I did not like how the beam has an abrupt cut off line ahead of you.  Then when you switch to high beams, the lighting seemed to stay the same, but only added about 3-4 feet to the forward edge of the light cut off area.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 30, 2014, 03:01:58 PM
It's all in the optics.  The standard buld has 2 filaments.  Both are the same value.  One is behind the other.  The reflectors are what make it happen.  I have to agree with you on the LED's.  Tried them.  Very expensive vs. the HID.  Strange you didn't like the HID's though.  Maybe it's the way you are looking at them.  Besides.  You sit behind them.  How would you know?  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: R. Dave Carr on August 30, 2014, 07:39:17 PM
Dave
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on August 31, 2014, 11:25:12 AM
Quote from: POLARACO
It's all in the optics.  The standard bulb has 2 filaments.  Both are the same value.  One is behind the other.  The reflectors are what make it happen.  I have to agree with you on the LED's.  Tried them.  Very expensive vs. the HID.  Strange you didn't like the HID's though.  Maybe it's the way you are looking at them.  Besides.  You sit behind them.  How would you know?  LOL

Never run the HID's Steve...just the good old fashion...and dead nuts reliable...glass faced Halogen bulbs.(http://www.moparfins.com/forum/smileys/smiley4.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on August 31, 2014, 03:49:26 PM
That's what I was telling you.  CeeBee makes a glass replacement that will accept those bulbs.  I agree with you.  The glass was the reason I did it.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 02, 2014, 07:28:41 PM
Weathers been rainy and cooling down here the last week or so.  So I figured it was time to install my heater hoses again.  But this time I had my new manual shut off valves, and a new vacuum coolant shut off valve as well.

I searched high and low for the "right" manual shut off valves I wanted to use.  Many hours were spent searching all over the internet until I happened across these babies!

4 Seasons 84706.  Used on early 70's dodge pick up trucks.

(http://static.summitracing.com/global/images/prod/mediumlarge/FSS-84706_ml.jpg)

And the vacuum operated shut off valve was not available for our trucks...at least with a 5/8 x 5/8 hose connections.  Maybe I just couldn't find it, but I searched high and low and never could find a direct OEM style replacement.

I found many that would "work" but looked hideous, IMO, but eventually found one I liked.

4 Seasons 74859. Used mainly on Ford Rangers from 2003 to 2008.

(http://i.ebayimg.com/00/s/MTUwMFgxNTAw/z/yckAAOSw7I5TwQ3j/$_35.JPG)

Now here it is all installed...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/August%202014/PICT0237_zpsf04e004f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/August%202014/PICT0237_zpsf04e004f.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/August%202014/PICT0238_zps1528e3f3.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/August%202014/PICT0238_zps1528e3f3.jpg.html)

Now next summer I can just turn off the valves and no heat, or coolant will enter the heater core to affect my AC temps. :D



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 02, 2014, 07:37:08 PM
Changed out the two air temp sensor in the intake.  The one for the grid heaters, the small more forward one, can be had through the aftermarket.  BWD WT3032 will get you the right one.  

The other one, it controls the on/off for the KSB.  I could not find an aftermarket replacement.  So I had to find a NOS one.  The OEM number on this one is...3921642

Here they are installed....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/August%202014/PICT0239_zps2d6b5487.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/August%202014/PICT0239_zps2d6b5487.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 03, 2014, 06:16:29 PM
Decided today to address the cab slipping from side to side on the cab mounts.  Took me a while to figure out what was going on, but that was what was happening.  Annoying as all heck, almost every corner, or big bump I took it would "clunk". :(

I thought I would be clever and grease everything up really well when I installed the new poly mounts.  Well this was one of the reasons things went haywire.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Sept%202014/PICT0006_zpsf65f965b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Sept%202014/PICT0006_zpsf65f965b.jpg.html)

I removed one side at a time, cleaned all the grease off in the parts washer, cleaned the body side with solvent and then finally re-installed.  Then snugged up the bolts.  Then I measured from side to side to make sure the cab was evenly spaced on the mounts.

One thing I did find was that once I had things in place, and I tightened up the nuts, that the nuts would bottom out on the shoulder on the factory bolts.  I think this was the other reason the cab was moving around on the mounts.  Not tight enough to hold things in place.

So I dug through my buckets of misc washers. Found some thick hardened washers from ???  But regardless I stacked two under each nut and it gave me enough addition thread to be able to torque them up to the factory 40-60ftlbs.

All done...right this time...;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Sept%202014/PICT0241_zpse7612dc1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Sept%202014/PICT0241_zpse7612dc1.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 03, 2014, 06:25:33 PM
A little trick I have been using while working on interior stuff.  You probably all know how hard it is to find the darn screw holes under the carpet and insulation, once you have removed a piece of trim, shift boot or other piece.

Well I figured out a way to make it relatively easy to get your item back in exactly the same place, and hit all the screw holes with little, to no effort.

Here is what I do.  First get some long finishing nails.  I think I use 3" nails.  Then once the carpet and such is back in position you use the finishing nails to poke through the carpet and insulation until you find the screw holes.

Like this...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Sept%202014/PICT0240_zpse3ea63a5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Sept%202014/PICT0240_zpse3ea63a5.jpg.html)

Then once all the screw holes have been found, just lower your piece over  the nails.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Sept%202014/PICT0242_zpsa15fe04f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Sept%202014/PICT0242_zpsa15fe04f.jpg.html)

Then just remove one nail at a time and screw it down into place.  Works perfect every time!


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 14, 2014, 05:29:26 PM
I have needed a new pass. side mirror.  The mirror had broken, and the original owner had installed one of those cheap shiny U-cut plastic mirrors.  Could barely see out of it.  And the power mirror motor gears were stripped as well.

Anyway I got a new "reproduction" mirror...well it looked nice in the box.  But went to install it and ran into some issues.  

First off the mounting holes were just slightly out of alignment, or too small?  Finally go the mounting bracket into place and found the routing for the power wires in the wrong spot.  So remove it again and change the location of the wires, then Install again.

Thought I was almost done and went to put the outer cover down and over the mounting bracket, and could to get it to line up, or install tight enough to get the lower set screw into place.  So I pulled it off again and checked it to the original bracket.  Looked like the clip they used that the screw goes into was too short.  So I swap those and tryed AGAIN!  

Now this time I was just able to push hard enough on the cover to get the lower screw in place...but barely.  But now the rubber seal around the neck of the shaft the mirror is on was pushed up and almost out.  Seems that the outer cover is just a tad too small...all around.

So removed it AGAIN! and this time pulled the original bracket and cover off the old mirror and installed it on the new one.  Installed it on the door and it all fell into place!  The actual mirror, motor and stuff seem to be fine...it was just the mounting bracket and cover that gave me all the grief.

So if you are considering buying one of these aftermarket mirrors be aware that things might not fit right.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 14, 2014, 05:35:21 PM
Also got some time to hunt down and stop a few front end rattles.  

First was the air cleaner assembly.  It was rattling in the metal bracket.  So I removed the air cleaner box and then put some sticky one side neoprene rubber foam along all the edges where it sits.  Nice and quiet now.

Then it was on to the front brakes.  Turned out when I redid the front end, and all the brakes, that I did not install the brake pads properly.  The outer pads I  did not bend over the tabs and makes sure they were tight on the calipers.  And the inner pads I did not use the anti-rattle clips.  

I have eliminated most of the rattle and clunks now.  And the truck just seems tighter, and better then ever.  Even more reasons to love it! ;)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 14, 2014, 07:14:40 PM
Quote from: thrashingcows
I have needed a new pass. side mirror.  The mirror had broken, and the original owner had installed one of those cheap shiny U-cut plastic mirrors.  Could barely see out of it.  And the power mirror motor gears were stripped as well.

Anyway I got a new "reproduction" mirror...well it looked nice in the box.  But went to install it and ran into some issues.  

First off the mounting holes were just slightly out of alignment, or too small?  Finally go the mounting bracket into place and found the routing for the power wires in the wrong spot.  So remove it again and change the location of the wires, then Install again.

Thought I was almost done and went to put the outer cover down and over the mounting bracket, and could to get it to line up, or install tight enough to get the lower set screw into place.  So I pulled it off again and checked it to the original bracket.  Looked like the clip they used that the screw goes into was too short.  So I swap those and tryed AGAIN!  

Now this time I was just able to push hard enough on the cover to get the lower screw in place...but barely.  But now the rubber seal around the neck of the shaft the mirror is on was pushed up and almost out.  Seems that the outer cover is just a tad too small...all around.

So removed it AGAIN! and this time pulled the original bracket and cover off the old mirror and installed it on the new one.  Installed it on the door and it all fell into place!  The actual mirror, motor and stuff seem to be fine...it was just the mounting bracket and cover that gave me all the grief.

So if you are considering buying one of these aftermarket mirrors be aware that things might not fit right.

Darned Chinamen.  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 16, 2014, 09:41:20 AM
I have been noticing a difference in the RPM my tach is showing when I'm cruising on the Hwy.  In the cool of the morning...about 5am...heading to work, I am seeing 2000rpm at approx 100Km/h.  But in the heat of the day, late afternoon heading home, I am seeing 1850-1900 going the same speed.

I never saw any fluctuations before when I was running the magnetic tach signal pick up on the harmonic balancer,  and this very same Isspro tach.

Only thing I can think of is maybe the CPS is going bad, or there is a weak link in the wiring?  And the heat of the day is causing a deterioration of the CPS signal?

Thoughts, ideas?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on September 16, 2014, 10:45:35 AM
That's a good one. If it were an auto I would say lockup or fluid temp was doing it, a manual, not so sure Tachometers are not temperature sensitive that I know of.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 16, 2014, 11:36:26 AM
MMMMMMM
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 20, 2014, 06:51:40 PM
I adjusted my valves today, they all were dead on.  I think the original owner always had his servicing done at the Chrysler dealership...so I think they must have stayed on top of the valve adjustment.  

I had to remove the fan and shroud so I could rotate the motor at the crank pulley so I could use the companion method to check my valves.  And since I had that all off I decided to toss on my new serpentine belt.

Also installed new valve cover gaskets and O-rings.  But on the way to pick up new O-rings I was driving the wife's 02 Concorde and the friggin drivers side inner door handle broke...Dooh!

So after getting the truck back together I had to make a run to the wreckers and get a new door handle.  They sure don't make these as serviceable parts now days do they!  Had to rely on my backyard engineering degree to get things fixed. ;)

Then Ol' Patches decided that it did not like it's positive battery cable connection.  Had to pull it all apart, slice out a little bit of the cable end so I could tighten it up a bit more.  Then re-assemble.

Then it was time for a bath....It was a good day! :)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 20, 2014, 07:03:37 PM
Never ends does it.

While under there I noticed a small hole in the inner rocker.  OK  Weather is good, so I'll tackle that in the morning.  Well my retired morning.  6 hours later, it's finally sealed up.  I took the running board off and my eyes opened right up.  Good thing I have all these tools and equipment.  Tomorrow I'll put some paint on it and put the running board back on.  You think I should look at the right side now?  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 01, 2014, 08:47:08 PM
Installed my 3200 governor spring today.  And reset the idle to about 750 with the A/C running.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0324_zpsff2011aa.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0324_zpsff2011aa.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0323_zps06811966.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0323_zps06811966.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 01, 2014, 09:01:54 PM
I also messed around with the idle screw, and nut.  Not only did it take me an a long friggin time to get that nut loose and out of the way, but I did not want to have to to try and adjust the idle with it in the stock set-up.

So I started looking at another way I could lock the idle shaft down, but still have it reasonably easy to do.

Here is the idle screw in the stock form...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT7677_zps002f04db.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT7677_zps002f04db.jpg.html)

Here's what I came up with.  I was looking for a long nut, or type of nut that I could mount on the front side of the idle shaft.  The problem with this is that if it's too short then you won't be able to loosen or tighten the nut down.  So what I found was a Nyloc nut that had the same fine thread as the idle shaft.  Then heated it up until the nylon melted out.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0326_zpsa1a342ef.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0326_zpsa1a342ef.jpg.html)

 Then I installed it backwards on the forward part of the shaft. This left it long enough to be able to get a wrench on the nut.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0328_zpseeb986fd.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0328_zpseeb986fd.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0329_zps0633d66c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0329_zps0633d66c.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0330_zps7834a73c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0330_zps7834a73c.jpg.html)

I turned the idle shaft around thinking that it would be easier to adjust from the front, but it was actually a lot more difficult to adjust it this way.  So I will be turning the shaft back around to the stock orientation, but leaving the nut on the front side!


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 01, 2014, 09:03:04 PM
Those P Pumps are so simple aren't they?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 02, 2014, 03:33:18 PM
Quote from: POLARACO
Those P Pumps are so simple aren't they?

Actually that's a VE pump, 89-93.  Not the P7100 P-pump that came in 1994 and later. ;) 

But yeah so elegant in there simplicity.(http://www.moparfins.com/forum/smileys/smiley1.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 02, 2014, 03:33:28 PM
Today was service day.  13 liters of oil , and new fuel and oil filters.  Air cleaner I do once a year.  Went to grease the drive line and I got one pump out of my grease gun and it ran out of grease, isn't that how it usually goes.(http://www.moparfins.com/forum/smileys/smiley5.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on October 03, 2014, 07:27:15 AM
I hate when that happens. Then you get a good deal on some item and you have it sit on the shelf until it becomes worthless! Story of my life.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 03, 2014, 04:48:21 PM
Quote from: thrashingcows
Today was service day.  13 liters of oil , and new fuel and oil filters.  Air cleaner I do once a year.  Went to grease the drive line and I got one pump out of my grease gun and it ran out of grease, isn't that how it usually goes.(http://www.moparfins.com/forum/smileys/smiley5.gif)



Food for thought
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 13, 2014, 07:01:31 PM
Well I've never been happy with my LineX box liner I had sprayed in a couple years ago.  The tailgate started pealing within the year.  And I don't know what I was thinking when I had the box sprayed with that stuff....I firmly believe in not putting any type of coating that is "water tight".  Simply because water ALWAYS gets beneath it and will cause issues down the road.

So the other day I'm shooting the $hit with my friend, and neighbour, and notice a small nick in the liner and it appeared to be lifting.  So I picked at it and this is what happened in about 10 seconds....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0346_zps791332de.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0346_zps791332de.jpg.html)

Then today I got back from making a run for bathroom reno supplies and notice other areas lifting.  So started to work on the liner seriously this time.

Quality product...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0345_zps398f3dcf.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0345_zps398f3dcf.jpg.html)

This is what about 3 minutes got me....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0349_zps37c9b60e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0349_zps37c9b60e.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0348_zpsaa4172be.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0348_zpsaa4172be.jpg.html)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 13, 2014, 07:05:21 PM
So figured what the heck, lets peal the rest off.  I've wanted the coating off for a while now, but assumed it was going to be a big hassle...turned out the crappy adhesion made is very easy to remove.

So took my neighbour an I less then 10 minutes to completely strip the box....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0350_zpse69975bd.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0350_zpse69975bd.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0352_zpsf893285c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0352_zpsf893285c.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0351_zpseb428cde.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0351_zpseb428cde.jpg.html)

Sure glad I got that out of there.  There was major water infiltration under the liner at the head of the box.  Rust starting in most areas near the "edge".  

Never again will I have any type of coating like this used anywhere on my vehicles.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 13, 2014, 09:30:11 PM
The professionally done version is next to impossible to hurt.  I had my 08 sprayed in and it was really tough.   there was no way the water would get into it.  
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on October 14, 2014, 06:03:12 AM
I have to agree with Steve on this one, your  application was simply a very bad one. If the place that did it is nearby, I would drop the old crap off, and if nothing else let them know piss poor prep causes piss poor results, no application of anything should ever peel off like that.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 14, 2014, 10:02:15 AM
Quote from: dana44
I have to agree with Steve on this one, your  application was simply a very bad one. If the place that did it is nearby, I would drop the old crap off, and if nothing else let them know piss poor prep causes piss poor results, no application of anything should ever peel off like that.

I might just do that.  I don't want another coating...but they should at least know how crappy their work was, and how cheesed off I am about wasting good money on this crappy coating.



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 14, 2014, 10:09:24 AM
Quote from: thrashingcows
Quote from: dana44
I have to agree with Steve on this one, your  application was simply a very bad one. If the place that did it is nearby, I would drop the old crap off, and if nothing else let them know piss poor prep causes piss poor results, no application of anything should ever peel off like that.

I might just do that.  I don't want another coating...but they should at least know how crappy their work was, and how cheesed off I am about wasting good money on this crappy coating.





Real blow in liners are 1/8" thick on the bed
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: firedome on October 14, 2014, 03:38:18 PM
Better to put in one of those molded removeable ones and just spray in oil or some such in the bed before putting it in, that's what Vermonters do and we deal with salt 6 months of the year. Youse Western guys don't know what real corrosion is  (...jeaulosy rearing it's ugly head..)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 14, 2014, 05:12:19 PM
Someone suggested that I contact the LineX head office and file a complaint that way.  Think I will start with that.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 16, 2014, 09:57:02 PM
Went to go see my diff guy today...doesn't sound good.  I think I have to have both front and rear diffs gone through.:(  

Not going to be cheap...but I trust this guy, he's passionate about what he does, and has done work for me on other projects.  Never a problem with his work.

But now I have to make a decision is I'm going to stay with the 4.10's or go with 3.54's.  I already have a set of Dana 70 3.54 gears that I picked up super cheap...they were removed from an original truck back in 1992 when the owner wanted 4.10's instead of the 3.54's for pulling his 5th wheel.

So since I needed to make a decision on what gears I want, I thought I'd toss on my HX35 this evening.  I wanted to see how my EGT's and fuel mileage might be effected by the 12cm exhaust housing and my PS intercooler, and the 4.10's.  

Everything went well until I fired it up and went for a drive.  The turbo sounds like it has a very tinny whine coming from somewhere.  And when I got out on the road it will not build any boost.  I think once I saw about 1-2lbs...that's it!  

I initial just had the waste gate wired shut.  But then second guessed myself and thought maybe my problem was that I had wired it in the open position.  SO I removed the wire and re-installed the wastegate actuator.  Went for another drive and same problem, nothing changed.

I have been reading threads on HX35's and could not come up with anything like my problem. Any idea of what the problem might be?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 17, 2014, 12:02:56 PM
Well in the light of day it was pretty obvious what the problem was....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/October%202014/PICT0366_zps0b428494.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/October%202014/PICT0366_zps0b428494.jpg.html)

Tad bit of interference between the impeller and the housing.....(http://www.moparfins.com/forum/smileys/smiley3.gif)  Guess my turbo rebuilding skills still need a little work.(http://www.moparfins.com/forum/smileys/smiley5.gif)

Now that there is wear on the intake housing, does that make the housing junk?  Or if I got a new cartridge for the HX35 can I install it and be good to go?



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 17, 2014, 02:23:52 PM
Not sure Brian.  It will probably not produce what is should.
May I suggest you run this past the guys on Igotacummins.com?  when you are done, ass this to your post  @Canadiandiesel   He lives up your way and will know.  He may even have something you can use and he's on your side of the line.  Spenser is a good guy and knows his schtuff.  I think he's an hour west of Calgary.  If that's a city
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: R. Dave Carr on October 17, 2014, 06:17:06 PM
My new boss was the service manager at Cummins NW here in Medford, and worked at Cummins NW for 26 years.  I can show him the pic and ask him too.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 17, 2014, 08:12:36 PM
There ya go.  
I can't tell how gouged it is.  Last I heard though, if it made contact with the housing, it's toast.  It needs that tolerance to compress properly.  The damage appears to be in the compression zone.  I could be wrong though.  I'm not a turbo guru
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 17, 2014, 08:16:07 PM
Quote from: carrman
My new boss was the service manager at Cummins NW here in Medford, and worked at Cummins NW for 26 years.  I can show him the pic and ask him too.

Thanks...I would appreciate that. It did make contact on the inside as well. 



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: R. Dave Carr on October 20, 2014, 06:02:26 AM
1.  Stop driving it!!!!  You will dust the motor with metal bits.
 
2.  Cummins DOES NOT sell center sections or rebuild kits any longer; it's turbo time.
 
 
Dave
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 20, 2014, 01:37:27 PM
Yeah What he said.  I think he put the old one back in.


So how does it feel to be working for a Burger Joint now?  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 20, 2014, 02:21:10 PM
Brian
I asked Spenser to look at the thread.  You should have gotten an email mentioning you in the thread.  I only hang with the best
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 22, 2014, 06:08:21 PM
Yes I put the old turbo back on.  I put maybe 10 min on the turbo before I removed it.

The turbo I used was a take off of a running truck...it had wear in the bearings, but had not made contact with the housing.  I decided to use one of those off shore rebuild kits...guess there was more slop in those "new" off shore bearings, then the worn original holset units....(http://www.moparfins.com/forum/smileys/smiley5.gif)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 22, 2014, 06:39:10 PM
I have a book on rebuilding those here.  I guess I could mail it up if you want it.  You can return it with my hub puller
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 23, 2014, 08:53:28 PM
Quote from: POLARACO
I have a book on rebuilding those here.  I guess I could mail it up if you want it.  You can return it with my hub puller

Thanks for the offer on the book Steve, but I'll be OK. (http://www.moparfins.com/forum/smileys/smiley2.gif)

  As for the puller...there was another board member who needed it and you asked me to send it on to him.  I can't recall who it was off the top of my head, but could probably dig it up if you need me to.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 23, 2014, 08:53:34 PM
Dropped the crewcab off at the diff guy to have them re-geared from 4.10 to 3.54, Power-Loc rebuilt, and both front and rear diff totally redone.  They were untouched and original with almost 270K on them.

I usually don't farm out repairs like this to other people.  But this guy I go to is amazing, and I trust his work and integrity.  And with the diffs being so old, and never any work done to them, I did not have the luxury to have the truck down for a week of more, if I was to run into unforeseen issues.

He will hopefully have everything back up and running tomorrow.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 23, 2014, 09:29:56 PM
Quote from: thrashingcows
Quote from: POLARACO
I have a book on rebuilding those here.  I guess I could mail it up if you want it.  You can return it with my hub puller

Thanks for the offer on the book Steve, but I'll be OK. (http://www.moparfins.com/forum/smileys/smiley2.gif)

  As for the puller...there was another board member who needed it and you asked me to send it on to him.  I can't recall who it was off the top of my head, but could probably dig it up if you need me to.


Lets find out who that is.  I need to keep track of it.  Was it Roger?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 23, 2014, 09:32:44 PM
Quote from: thrashingcows
Dropped the crewcab off at the diff guy to have them re-geared from 4.10 to 3.54, Power-Loc rebuilt, and both front and rear diff totally redone.  They were untouched and original with almost 270K on them.

I usually don't farm out repairs like this to other people.  But this guy I go to is amazing, and I trust his work and integrity.  And with the diffs being so old, and never any work done to them, I did not have the luxury to have the truck down for a week of more, if I was to run into unforeseen issues.

He will hopefully have everything back up and running tomorrow.


I went from 373's to 342's.  I hate the work.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 24, 2014, 09:36:37 AM
Quote from: POLARACO
Quote from: thrashingcows
Quote from: POLARACO
I have a book on rebuilding those here.  I guess I could mail it up if you want it.  You can return it with my hub puller

Thanks for the offer on the book Steve, but I'll be OK. (http://www.moparfins.com/forum/smileys/smiley2.gif)

  As for the puller...there was another board member who needed it and you asked me to send it on to him.  I can't recall who it was off the top of my head, but could probably dig it up if you need me to.



I will see if I can find out who I sent it to.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 24, 2014, 09:38:51 AM
Steve...it went to Roger (Firedome) last year around the beginning of Feb/2013.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 24, 2014, 12:25:44 PM
That's what I thought!  At least it's close to home.

What are we doing about your turbo?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 24, 2014, 07:22:34 PM
Quote from: POLARACO
That's what I thought!  At least it's close to home.


As of right now nothing.  I am saving up for a "NEW" HX35 unit.  But in the mean time a local 1st Gen'er says I could use his spare H1C with a 14cm housing.  He ran it for about 10K Km's before upgrading again to a HE351CW.   So I will see where that goes.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 24, 2014, 07:22:54 PM
Just got back from picking up the truck...very happy with everything!  He told me both diffs were in good shape, someone relatively competent had been in there at some point.   Power loc only needed new clutches, and the front diff didn't even need new bearings.   

Re-geared to 3.54's, I had an OEM ring and pinion I had picked up super cheap.  I went to a old fellows house to pick up a compressor and when he saw my crewcab we got to talking.  Turned out he had recently sold his 92 reg cab dually and had some leftover pieces.  I got a mint, but terribly bent one ton tailgate, Dana 70 3.54 ring and pinion, repair manual and some other stuff for $125!

Anyway he only had to replace the front gear set, with a mint OEM set.  And he couldn't say enough about how clean and easy my stuff was to work on...such a change to what he usually has to deal with.

All in all a very fine experience!  I would highly recommend him to anyone in the area!

If anyone is interested this is his business....

 https:/www.facebook.com/DifferentialSolutions (http://https:/www.facebook.com/DifferentialSolutions)

or the Physical addy is...

33149 London Ave #16, Mission, BC V2V 4P9
Phone - (604) 723-8250
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 24, 2014, 08:19:08 PM
I put a 351 in my truck.  It wasn't much of an upgrade physically, but is more responsive.  I think it was 9 MM bigger.  If there is a lag, you can't feel it.  Thing runs like a gasser.  
You did some mighty fine work there.  When you do stuff like this, something is bound to happen.  It can't be avoided.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on October 24, 2014, 09:37:27 PM
Brian




3.  It rains allot there  (http://www.moparfins.com/forum/smileys/smiley17.gif)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 25, 2014, 07:04:45 AM
Quote from: POLARACO
Brian





Thanks for the kind words Steve...Now I will go towel off from the rain.(http://www.moparfins.com/forum/smileys/smiley2.gif)  (http://www.moparfins.com/forum/smileys/smiley36.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on October 25, 2014, 12:01:02 PM
Just got back from a drive with a GPS unit to confirm my current speedo reading, to my actual speed, now that the gearing has been changed.

I first removed the ratio adapter that was in there.  It was a 1.04 unit, which was a 4% increase in signal speed for the 4.10's.  I then re-installed the VSS straight off the transfer case.

I had read that after you do this you go for a drive, then drive 50mph (80kph) and check your speed.  Mine was 67kph. Then divide your speedo reading into the 80kph and it gives me 1.194.  So I need a ratio adapter with approx a 1.2 over drive ratio, or 20% increase in signal speed for my speedo to be accurate.

I'm going to the wreckers in a bit to see if I can find anything. ;)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 05, 2014, 05:19:08 PM
Well yesterday I received my ratio adapter for my speedo.  I figured out that I needed a +20% VSS signal to get my speedo to read right.

I went with PATC.  Very happy with their service and product.

http://www.transmissioncenter.net/speedometer_calibration_______va.htm

Here's some pics...

Original and new unit....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0400_zps11e65b1d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0400_zps11e65b1d.jpg.html)

And the ratio on the OEM unit.  The 1.04 equals a +4% VSS signal.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0401_zps5b828d51.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0401_zps5b828d51.jpg.html)

And the new ratio at 1.20.  So +20% VSS signal.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0402_zps9a623309.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0402_zps9a623309.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 05, 2014, 05:24:00 PM
The ratio adapter from PATC must be a generic piece to service more then one application.  SO it came with a small adapter kit as well.

I needed the square head for the transfer case side...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0403_zps0454b6a6.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0403_zps0454b6a6.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0404_zps5837ed67.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0404_zps5837ed67.jpg.html)

And the VSS side I needed the plastic insert so it would except the VSS square drive shaft.  You can see it in the back ground.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0405_zps56944d76.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0405_zps56944d76.jpg.html)

And installed and ready to go.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0406_zpsc0f0a59c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0406_zpsc0f0a59c.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 05, 2014, 05:28:37 PM
Today was the old car shuffle.  Move my wagon into storage....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0409_zpse7355e08.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0409_zpse7355e08.jpg.html)

And bring home my Desoto...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0411_zpsd98ae631.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0411_zpsd98ae631.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: R. Dave Carr on November 05, 2014, 05:45:48 PM
After seeing the pic of the new adapter installed, I now know how one would get a modern electric speedo to work off an old style trans.  I'll be damned.  I see the sensor looks like it's just a hall sensor and a tone wheel that's turned by the speedo drive gear!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 05, 2014, 06:49:13 PM
Not quite sure what you are saying Dave.  Brian installed a mini gear box on to the electric sensor.  That signal generator ran the transmission in later years as well as the speedo.  Polaraco has one too
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 06, 2014, 05:41:40 PM
Today I finally decided to get off my duff and make a spacer for my throttle pedal.  When I installed the new carpet I added extra sound deadening and insulation, and the skinny pedal has never had full travel.

So I dug out some hard fiberglass pieces I had laying around. Scraps form my neighbour who's a commercial fiberglass guy. The pieces I used was about 7/16" thick.  Used a spare pedal assembly to mark off the piece I needed.  Little cutting and drilling got me this.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0417_zpsd1b7df0d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0417_zpsd1b7df0d.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0418_zps1cf39e7b.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0418_zps1cf39e7b.jpg.html)

Needed a little fine tuning to clear the firewall insulation. Then I cut a piece of neoprene foam gasket material and applied it to the firewall side to help seal out the elements.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0419_zps50bb4e60.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0419_zps50bb4e60.jpg.html)

Once that was done I moved the ball on the IP arm to the inner hole, and then re-adjusted the throttle assemblies.  Much better now...have full throttle and barely have to press the pedal to make it go.

I also decided to spin my fuel pin to the deep side while I was right there.  Went for a quick drive around the block and it seemed to have a little more grunt.  Probably the combo of full throttle travel, and the extra fuel being supplied to the motor.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 08, 2014, 02:48:43 PM
Yesterday I installed the aluminum upper wheel opening mouldings from the 84 side trim.  I have been debating if I should run the 91-93 big black wheel opening flares.  But after my last junk yard run and seeing the dodge rams and dakota with front and rear wheel rot due to these types of flairs, I couldn't justify putting them back on.  Especially since this is my daily drivers.

I also installed my aluminum mud flaps.  And today I gave Ol' Patch's a bath and some fixes hear and there, mostly where water was leaking in, and some surface rust had started.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0423_zps2c21d5ad.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0423_zps2c21d5ad.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0424_zps3ee6d9b6.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0424_zps3ee6d9b6.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: 300rag on November 08, 2014, 03:04:52 PM
Any more on the Line-x?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on November 08, 2014, 03:09:18 PM
Yeah, chrome (stainless) accents always set off a vehicle.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 08, 2014, 05:18:51 PM
When are you going to paint this thing?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: R. Dave Carr on November 09, 2014, 10:24:41 AM
Some of the import stuff I used to play with, folks install later model dash clusters and such sometimes, and I often wondered how do you get an electric speedo to run off of a cable drive.  Now I know.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 11, 2014, 05:51:24 PM
Quote from: 300Rag
Any more on the Line-x?

I've called and left messages twice with Corporate Line-X...No call back.  And the Local Line-X dealer who did the crappy job, has refused to call me, unless I call him first.

So I guess it's time to start my on-line negative PR campaign. (http://www.moparfins.com/forum/smileys/smiley15.gif) 

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 11, 2014, 05:53:13 PM
Quote from: dana44
Yeah, chrome (stainless) accents always set off a vehicle.

Wish I could find a set of full wheel opening moulding for this style of truck...but don't think they ever made them?

I would even use a set  from another make, ford, chev etc...if I could make them work. (http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 11, 2014, 05:53:51 PM
Quote from: POLARACO
When are you going to paint this thing?

No time soon.  My daughters love Ol' Patches just the way he is. (http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 11, 2014, 05:54:42 PM
Quote from: carrman
Some of the import stuff I used to play with, folks install later model dash clusters and such sometimes, and I often wondered how do you get an electric speedo to run off of a cable drive.  Now I know.

Glad you learned something new.  I had to learn all this myself. (http://www.moparfins.com/forum/smileys/smiley4.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 11, 2014, 07:00:04 PM
Quote from: thrashingcows
Quote from: POLARACO
When are you going to paint this thing?

No time soon.  My daughters love Ol' Patches just the way he is. (http://www.moparfins.com/forum/smileys/smiley2.gif)

Sneak in one panel at a time.    By the time you're done, she won't care anymore.  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 13, 2014, 10:11:25 AM
Brian
FYI   Your post on I gota has gone viral!  Yer famous now.  LOL   
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 13, 2014, 04:13:44 PM
Quote from: POLARACO
Brian

Woo Hoo...my 15 sec of fame!!(http://www.moparfins.com/forum/smileys/smiley5.gif)(http://www.moparfins.com/forum/smileys/smiley36.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on November 13, 2014, 06:01:58 PM
Who cares as long as you get results, right?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 14, 2014, 09:49:59 AM
Pretty much that is all I'm looking for....a resolution to this issue. 

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 14, 2014, 02:31:46 PM
Guess we better stir the pot
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 26, 2014, 06:02:29 PM
Quote from: POLARACO
Guess we better stir the pot

Well I was contacted by the Canadian Manager, so the regional managers boss?  I responded to her over a week ago...still no response....AGAIN!

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 26, 2014, 06:02:47 PM
They shut the power off in my neighbourhood today....Hydro upgrades.  So I took the opportunity to build my Headlight relay system.

Now my donor 93 for my crewcab was a Canadian truck, so it came with DRL (Daytime Running Lights).  So I had to use a different wiring schematic.  

I used this one written up by Jim Lane over on the DTR....

http://www.dieseltruckresource.com/dev/headlamp-relays-canadian-trucks-t310460.html

Unfortunately there are a few bugs to work out.  DRL don't work, and the High beam indicator on the dash stays on all the time.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 26, 2014, 07:39:41 PM
LOL

Anything new on the liner?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 27, 2014, 07:31:19 AM
Quote from: POLARACO
LOL


I've lucked out for the most part.  This Headlight relay system had not been done by any Canadian 1st gen before....at least not fab'd up and the results posted up on the board.  So I was really the first one to do the "Theoretical" system.  Like Jim Lane stated the system should work, at least in his head, just needed someone to actually build it and post the results.

No communication from the grand overseer of all of Canada Line-X.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 27, 2014, 12:50:59 PM
OK
Shall we light a fire under their arses?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 27, 2014, 02:35:13 PM
Quote from: POLARACO
OK

I'm a patient man....revenge is best served well aged, and cold. (http://www.moparfins.com/forum/smileys/smiley2.gif)(http://www.moparfins.com/forum/smileys/smiley15.gif)  I'm goign to wait for the results of the BBB complaint.  If no resolution after that, then off to the media.  If nothing after that, then will take legal action.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on November 27, 2014, 05:02:14 PM
They on facebook?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 27, 2014, 08:25:42 PM
Quote from: POLARACO
They on facebook?

Think so...but hold off.  I got an E-mail that maybe something is happening.  Will let you know in a day or two.(http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on November 28, 2014, 10:45:28 AM

Last night while driving home after a movie with my family, the Pyro
decided to stop working.  I tried hooking and hooking the leads from the
 Thermocoupler last night, dug under the dash to see if the power and
ground were still hooked up...everything looked fine.



So after i came in from the monsoon rains...of course...I dug around
on-line and found a PDF file on how to test the early Isspro EV gauge
system.



Here is a link for others....



http://www.isspro.com/TROUBLESHOOTIN...leshooting.pdf (http://www.isspro.com/TROUBLESHOOTING%20DOC/EV%20Pyrometer%20Troubleshooting.pdf)



Tested everything this morning, and it seemed that the thermocoupler was
 the culprit.  So went down to BD diesel...yup they are 3 minutes from
my house...(http://www.dieseltruckresource.com/dev/images/smilies/wink.gif)  Bought a new T-coupler, and when I got home I tested the new T-coupler and it gave me the exact same readings as my old one.



So the problem clearly was elsewhere.  After a little digging and closer
 inspection I found one of the crimped spade terminals on the wiring off
 the amplifier had corrosion.  Pulled the old spade terminal, cleaned up
 the wiring and installed and new connector...works like a charm now!!



And just in case someone is testing their T-coupler using the info in
that PDF file.  The resistance they say you should be getting off the
cold T-coupler should be less then 1ohm.  My used T-coupler, and the new
 one both read 3.0 to 3.5 Ohms.



Also the voltage from the amplifier, to the gauge...white and grey wires, should show .8V...mine was .34V and it works fine.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 01, 2014, 08:26:34 PM
I spent two days, and 800+ Km's, helping my brother move two of his Ford trucks.

It started on Thursday Nov 28 at about 4pm.  I picked up my brother from his work, and grabbed one of their Tandem axle, tilt deck car trailers....nice trailer!  We then went back to his place and loaded up his 72 Ford 4x4.  We finally got going about 6pm.  It was dark, cold (-8*C), and windy and starting to snow.  

We traveled about an hour until we hit the Flying J truck stop to get some eats, and repair a couple lights on the trailer.  Wind was so bad that I was seeing 12-14lbs of boost on level hwy surface!

Here what we looked like....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0441_zpsf96c64ed.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0441_zpsf96c64ed.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0442_zpseb91a34d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0442_zpseb91a34d.jpg.html)

Now the next 4-5 hours we were up in the mountains of BC.  It was friggin cold, and had been snowing the last day or so, and was continuing to snow.  The roads we were on were single lane each way, and twisty, up and down, was packed ice with snow covering it.  Top speed was maybe 70km/h, but mostly 50km/h.

First fill up about 10:45pm.....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0444_zpsf72e2583.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0444_zpsf72e2583.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on December 01, 2014, 08:35:23 PM
Works for me. Just did a travel trip from southern to northern California to see the daughter for T-day, 768 miles one way, had some slow traffic heading back on Saturday, but still averaged a cruise speed of 80mph many times, and 28.4 mpg with the PT Cruiser. I don't mind the rain, but will admit, would rather be in a B or C body Mopar than a Ford or Chevy when driving in the snow, have done spinouts in them, never the Dodges.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 01, 2014, 08:38:45 PM
That was the last of the "Good" roads.  The next 100kms was mostly wash board dirt roads covered in packed ice and snow.  Not a lot of gravel tossed down either for traction.  Nasty climbs up and down....switch backs and 8-13% grades!  

I was surprised how well Ol' Patches did.  Thank goodness I had those diffs rebuilt...that power loc in the rear diff was one busy piece of equipment I can tell you that!

I spun out on one hill.  It was a sheet of ice under the snow cover, and now gravel to be seen.  Even in 4Lo it wouldn't continue up the hill.  Thankfully I had brought my cheapy cable chains with me.  We ended up putting one chain on the back RH side, and one on the LH front.  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0446_zpsddb71cf0.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0446_zpsddb71cf0.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0445_zpsed08f855.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0445_zpsed08f855.jpg.html)

And what the truck and trailer looked like by this time....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0447_zpse014884d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0447_zpse014884d.jpg.html)

I gently got under way and was able to get enough traction to get to the top of the hill.  We continued on, again at top speeds of 50km/h until we were about 10Km's from our destination.  We had one last hill to climb.  This one covered about 1200ft in 10km's....I made an attempt and spun out on the first section.  Put it in 4Lo and made it to pull out and dropped the trailer.

By now it was 3am and we were done for the night.  Up to my brothers place and crash for a few hours.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 01, 2014, 08:44:03 PM
Next morning it was -20*c with a windchill about -25+*C!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0448_zpsdf5f2f48.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0448_zpsdf5f2f48.jpg.html)

We went back down the hill with hopes the road crews had tossed more rock on the hill...not really.  So we hooked back up to the trailer, and then got the old ford running, and he drove it up while I brought up the trailer.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0450_zps8e8313de.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0450_zps8e8313de.jpg.html)

Here are a couple pics from that climb.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0451_zpscb22379a.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0451_zpscb22379a.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0452_zpsa19ba9f6.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0452_zpsa19ba9f6.jpg.html)



Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 01, 2014, 08:56:25 PM
We then had to haul out his old 52 Ford from storage, clean and sort it out, bolt things down and get it on the trailer....there was no motor in this one. ;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0455_zps4e8a46ee.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0455_zps4e8a46ee.jpg.html)

We finally got out of there some time around 1:30pm. The roads were not any better then the night before, and it was dark by 4:30pm.  

Stopped to check trailer and chains...Gorgeous scenery.  That pile of loose rock, down between the hills, is a Dam!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0457_zpsf7194215.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0457_zpsf7194215.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/November%202014/PICT0458_zps33664b41.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/November%202014/PICT0458_zps33664b41.jpg.html)

Didn't spin out on the way down, guess the slightly lighter truck helped there.  But I did use the 4wd a little more on some of the steep switch back grades. It took us until about 10pm to get to my brother place down here.  Quick drop of the trailer at his place, then I had to rush home, get cleaned up and get to bed so I could get up for work at 4am!

Over all I was pretty happy with the way the crew performed.  Think I averaged about 13mpg for the trip.  But considering that a straight away was probably less then 1/4 mile, and most of the trip was spent in 3rd gear doing 50km/h at 2000rpm.  I think it did OK.

Now I have to wait for it to warm up so I can give Ol' Patches a good bath. ;)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on December 01, 2014, 09:02:46 PM
Ice road truckers
I haven't seen those traction strips in years!  I used ot have a set.  Been looking for a set of chains with the straps that go through the wheel.  Haven't found what I want yet.  Since I have a RWD, they may be needed.  I might be ablt to make something with chain and bungee cords.  Just to get out of a jam
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on December 20, 2014, 04:33:48 PM
Rear brakes have been squealing and giving me issues since I got back from my winter haul trip.  I tried adjusting up the star wheels, but only one side would hold the adjustment.  So I decided to get new adjustment hardware kits for both sides.

I decided today I would get this done...friggin rained like crazy, but oh well...if you live on the 'wet" coast and are afraid to get wet, then you will never get anything done on your vehicle. ;)

Here's the kit and the parts I replaced.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/December%202014/PICT0004_zps5cc18a0e.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/December%202014/PICT0004_zps5cc18a0e.jpg.html)

When I pulled the LH side I found the inner seal is shot already.  It appears that the inner bearing is starting to go.  Think on my winter haul trip things got hot enough to cook the inner seal....thank goodness for the arctic weather we were driving in or I could have toasted that hub!

I will be ordering all new inner and outer bearings, and seals, and probably a spindle nut kit to get rid of the nylock nuts and keepers.

(http://https:/venturestruckparts.com/images/Dana%2030%2044%20GM%20Bolt%20Spindle%20Nut%20Kit%20Both%20Sides%20Used.jpg)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 03, 2015, 05:11:32 PM
Today I decided to get my lazy a$$ in gear and get a few things done on teh crewcab.

I first swapped out the transmission mounts in poly back to the good old rubber.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/Replacingpolywithrubber_zps271ef418.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/Replacingpolywithrubber_zps271ef418.jpg.html)

Then I installed all new bearings, races, and seals on the rear hubs.  I had one bad seal, and an inner bearing that looked a little dicey.  I ordered everything in National Brand...since the info i could find on-line stated that these were still made in the USA. ;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0029_zpsa08f8871.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0029_zpsa08f8871.jpg.html)

And the brass drifts I purchased a year or so ago again came in handy when installing the new races.  Brass drifts, and a 2lb brass hammer should be in everyone's tool box. ;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0030_zps01981077.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0030_zps01981077.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 03, 2015, 05:23:59 PM
Also decided I would build some winter front inserts for the grille.

First I made templates out of some thin cardboard.  You only need to make one for the upper, and one for the lower and then just flip them for the other side.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0033_zps95212ad1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0033_zps95212ad1.jpg.html)

I grabbed some of that corrugated plastic sign material from a Home Depot when they were clearing out the seasonal summer plants....Free!  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0034_zps6af53f8f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0034_zps6af53f8f.jpg.html)

I just drilled a couple holes, and then used some long zip ties to hold them in place.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0038_zps25027841.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0038_zps25027841.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0037_zps52b3543d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0037_zps52b3543d.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on January 03, 2015, 05:27:48 PM
Cute!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 03, 2015, 06:49:19 PM
I use brass bar.  When the end gets beat up I just cut it off.  Use a dead blow hammer
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Snotty on January 04, 2015, 07:04:54 AM
Change the title of this post - wrong year listed.  (Not to mention Dodge did not build a Cummins truck in '84.)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 06, 2015, 08:21:22 PM
Quote from: Snotty
Change the title of this post - wrong year listed.  (Not to mention Dodge did not build a Cummins truck in '84.)

Done....Hope it's less offensive now....(http://www.moparfins.com/forum/smileys/smiley2.gif)(http://www.moparfins.com/forum/smileys/smiley36.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Snotty on January 08, 2015, 08:37:18 AM
Not offensive, just confusing.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 08, 2015, 06:10:14 PM
Quote from: Snotty
Not offensive, just confusing.

I know...just bugging you....(http://www.moparfins.com/forum/smileys/smiley2.gif) (http://www.moparfins.com/forum/smileys/smiley4.gif)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 15, 2015, 05:26:53 PM
Having some brake squeal and wear issues on the crewcab.

Drivers side is wearing fine, inside and outside pads are making contact fine. But pass side is hanging up and both pads are not engaging properly. I have cleaned caliper track surfaces of all paint and debris. There is a little bit of wear on the caliper brackets where the inner pad rides, but I don't think it's enough to cause any "hang up" issues. Everything looks good, but that one side refuse to work properly.

With the drivers side doing most of the front braking I now have a warped rotor as well...:whyme:

Also the front end is starting to develop a "clunk" or ""bang" when I angle up to get a line on backing into a parking spot.  When I turn the wheel to either side, left or right, and start to back up and turn the wheel to adjust my angle...occasionally it will make this noise.  

It doesn't have to be a full lock turn to make the noise either.  Had it make the noise today when I left work, making a left out of the parking stall....first time it's done it going forward.

Going to have to climb under there tomorrow and see if I can find what's going on.


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 16, 2015, 03:31:24 PM
And the caliper is not frozen up?  Sometimes they can go bad out of the rebuilders shop
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 16, 2015, 05:27:34 PM
Quote from: POLARACO
And the caliper is not frozen up?  Sometimes they can go bad out of the rebuilders shop

Could be....I'm goign to have my neighbour help me tomorrow and see if I'm getting good pressure to the caliper, and maybe run the piston out farther in the bore and then crank it back down and in.  Maybe it will work something loose and it will function properly afterwards?

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 16, 2015, 05:27:39 PM
Well it was a beautiful sunny day here today, Probably about 10*C (50*F) in the sun, so I climbed around under the front of the truck with my pry bar and start trying to find the source of the clunk/bang.

After about 5 minutes or so I finally located my noise.....turns out the rad support bolt had come loose.  Both had backed off at least 1/2".  So I drained the cooling system, removed rad and shroud, and then contorted myself to be able to hold a wrench on the top of the bolt, and then tighten up the nut from underneath with a long extension and ratchet.

I had used a couple used stover nuts when I assembled it the first time, but clearly they had lost their "stover" and were just regular nuts. ;)  So I tossed on a couple new stover nuts and torqued it all down.

Hope that eliminates that noise.  :)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 16, 2015, 06:46:32 PM
Now you have to get it to stop straight
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 17, 2015, 09:12:11 AM
Quote from: POLARACO
Now you have to get it to stop straight

That's the thing...even though the left side is doing most of the front braking....it does not pull....???

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 17, 2015, 11:46:04 AM
Is the inside worn more than the outside?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on January 19, 2015, 11:23:47 AM
What about the brake flex line having damage inside and fluid is causing a block because the inner lining has a hole or crack and fills with fluid, blocking the pressure? As far as the steering cluck goes, check the bolts on the steering box itself, which can come loose, or a crack in the frame where it attaches. Didn't you do work on that? Look for shiny spots for contact locations.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 21, 2015, 04:11:13 PM
Yes I added the extra Ramcharger steering brace.  And put larger, and proper attaching hardware as well.

I did have one of the power steering box bolts come loose.  My guess is that another one is loose as well.  I'll pull it off to double check, and perhaps lock tight them in place this time if I find them loose.

Thing is though I have wedged my pry par in and around the steering box and it all seems tight and secure.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 22, 2015, 01:38:16 PM
Well I decided I would getting the front end to ride a bit smoother with the help of the thread below and user sevnt300 and his findings. Those "smooth ride" parabolic springs I installed during the 4wd conversion really did not smooth anything out in the ride....actually I think it made it stiffer. :(

Well Sevnt300 over in this thread...http://www.dieseltruckresource.com/forums/1st-gen-ram-all-topics-93/front-suspension-upgrade-301721/page10/ ....Post #138.  He has a cummins long box crew as well with these springs was not happy with the ride either.  He did a lot of R&D work to finally come up with a ride he was comfortable with.

So first I had to pull apart an old set of rear springs and find two leafs that would be 34" long and allow an even 17" on each side of the center hole.  Think it was the 3rd leaf up from the bottom.

One side already had a hole for the spring clamp and was 17", the other required about 3" to be cut off.  Then I had to tapper the tip.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0011_zps148c1651.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0011_zps148c1651.jpg.html)

I then went down to the shop that sold me the Smooth Ride springs...they are local....and picked up some new wear tips and spring clamps.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0012_zps526b95b7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0012_zps526b95b7.jpg.html)

The rubbers that came with the new spring clamps would not work with their style, so i used some neoprene sheet I had to cut out some new ones that would.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0014_zps3a6e3a00.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0014_zps3a6e3a00.jpg.html)

Then I had to drill three 1/2" holes in each spring.  One for the wear tip, and two for the new spring clamps to lock into.  I positioned the spring clamps 6" back from the wear tips.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0013_zps6ac13aa7.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0013_zps6ac13aa7.jpg.html)

Tossed on some paint and got ready to do the swap.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 22, 2015, 01:47:16 PM
Did the spring prep last week in teh evenings.  So decided since I had a couple days off I would tackle the swap today.  Took about 5 hours from start to finish.

First was to get the sway bar end links off, and the shocks as well.  Then remove the U-bolts.  Once all the was off I could start to jack up the truck to give me enough clearance to loosen the retaining bolt in the center of the spring pack and remove the lower spring.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0016_zps60cd0004.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0016_zps60cd0004.jpg.html)

Ready to remove lower spring.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0015_zpsfca56d15.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0015_zpsfca56d15.jpg.html)

Here is a comparison of the second spring in this smooth ride set-up, and the new one that is going in.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0019_zpsd0abda31.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0019_zpsd0abda31.jpg.html)

Of the 3 wear tips on the lower springs only one was still in place and secure.  The others had broken loose.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0017_zps22743455.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0017_zps22743455.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 22, 2015, 01:55:24 PM
Transferred the two plates from the original pack to the new spring and installed.  Required a couple clamps to compress the spring so I could get the threads started on the center bolt.  Then it was just snug everything up and make sure all the plates and springs stayed in alignment.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0021_zps501a31d5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0021_zps501a31d5.jpg.html)

Then once both side were done I had to lower the truck back down and get everything to line up.  Had to go back and forth taking a few inches out of each side to slowly lower it back down.  Once the weight was on the springs I installed the spring clamps.  Then finished re-installing everything.  Only had to cut about 3/4" to 1" off the U-bolts to make up for the difference in spring pack thickness.

All done and ready to go.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Jan%202015/PICT0023_zps3232f9b2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Jan%202015/PICT0023_zps3232f9b2.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 22, 2015, 02:00:29 PM
I measured from the ground to the top of the wheel well arch before I started, and after I was done, lost exactly 1.5" on each side.  And I can say the ride is like night and day!!  I used to cringe every time I ran over a manhole cover in the road....now it just absorbs the bump and you barely feel it.

I couldn't be happier with the ride so far.  Although I've only put a couple miles on it, but so far so good!
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on January 24, 2015, 04:27:19 PM
Well today I decided to see where my "bang/Clunk" was coming from in the front end.  I was pretty sure it was the steering box, but had my neighbour crank the wheels back and forth while I watched and listened.  

Sure enough the box torqued in one direction, then when direction and torque was applied in the opposite direction I got a bang.  And you could see that the steering box had a lot of movement.

Pulled the battery, and IC tube on the DS and lifted up the splash guard.  Found one bolt half out and loose.  One other was just starting to loosen up.  So I removed the two I could remove, cleaned them up and blue loctited them in place.  The other two I backed out as for as I could, more blue loctite, and then tightened back up.

Cycled the steering again once everything was back together and all seems well. 

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on January 24, 2015, 06:50:21 PM
Someone said steering box.  I'm surprised you have so many loose bolts though.  Too many Burger Kings?  LOL  I thought i was the one who forgot shtuff

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 08, 2015, 06:48:32 PM
Quote from: POLARACO
Someone said steering box.  I'm surprised you have so many loose bolts though.  Too many Burger Kings?  LOL  I thought i was the one who forgot shtuff

It was that brutally rough Ice Road trucking I did hauling my brother trucks up into the interior and back.  The roads were washboard for at least 200 miles!  Shook a lot of stuff loose on Ol' Patches.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on February 08, 2015, 07:46:08 PM
Good thing you're not an Ice Road trucker.  LOL
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 09, 2015, 06:18:55 PM
Quote from: POLARACO
Good thing you're not an Ice Road trucker.  LOL

If it was a company truck then I wouldn't care so much....(http://www.moparfins.com/forum/smileys/smiley2.gif) (http://www.moparfins.com/forum/smileys/smiley36.gif)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 14, 2015, 05:25:16 PM
Well i redid the rear brake hubs a few weeks ago, new bearings and seals, but yesterday on my first day off in about a week I noticed that there was gear oil on the ground by the passenger side rear tire....Doooh!

So today I tore into it to see how bad it was....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Feb%202015/PICT0019_zps5c44e941.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Feb%202015/PICT0019_zps5c44e941.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Feb%202015/PICT0021_zps7518b26c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Feb%202015/PICT0021_zps7518b26c.jpg.html)

All that oil everywhere...that can't be good.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Feb%202015/PICT0023_zpsbe5625ec.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Feb%202015/PICT0023_zpsbe5625ec.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 14, 2015, 05:29:25 PM
Turns out I nicked the inner seal on the threads when installing it.  Gouged the seal and popped the spring loose as well.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Feb%202015/PICT0022_zpsb0b2e972.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Feb%202015/PICT0022_zpsb0b2e972.jpg.html)

And with all that oil everywhere the rear shoes were toast!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Feb%202015/PICT0024_zpsa8fd8558.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Feb%202015/PICT0024_zpsa8fd8558.jpg.html)

So off to the parts store for some new Wagner riveted 12x3 shoes, and SKF inner seals....Did not want to use the raybestos bonded units. ;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Feb%202015/PICT0026_zps2114e840.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Feb%202015/PICT0026_zps2114e840.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Feb%202015/PICT0027_zps0356fd6c.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Feb%202015/PICT0027_zps0356fd6c.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 14, 2015, 05:34:43 PM
Lots of cleaning to get that gear oil off everything.  But finally got everything clean up and start re-assembly.  This time I used some black electrical tape over the threads to smooth things out just in case I get weak and wobbly trying to lift that drum and hub into place. ;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Feb%202015/PICT0025_zpsb1deea72.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Feb%202015/PICT0025_zpsb1deea72.jpg.html)

So it turned into an expensive day.  Amazing what a small nick in a seal can end up costing you....a big chunk of change, and half a day. ;)
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: dana44 on February 14, 2015, 06:45:28 PM
Good job. Yeah, mistakes get made, at least you didn't have hard parts that got destroyed before you realized something was amiss.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 14, 2015, 07:03:33 PM
Quote from: dana44
Good job. Yeah, mistakes get made, at least you didn't have hard parts that got destroyed before you realized something was amiss.

Yeah it wasn't too bad....lost about 1/2 liter of fluid though!   And I learned a little trick to help make sure the seal never gets wrecked again. (http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Bill on February 15, 2015, 03:23:35 AM
Funny,  I just learned that same trick.  thanks for the education.

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 18, 2015, 09:46:08 AM
Quote from: czervika
Funny,  I just learned that same trick.  thanks for the education.

No problem...Gotta share so we all can learn right...(http://www.moparfins.com/forum/smileys/smiley2.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 21, 2015, 06:34:03 PM
Absolutely a gorgeous day here today. Clear and sunny and probably a good 15* to 20*C in the sun (65*to 70*F).   Wife and daughters went out shopping, so I decided to give Ol' Patches a good cleaning inside and out.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Feb%202015/1TruckwashFeb212015_zpsb371777d.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Feb%202015/1TruckwashFeb212015_zpsb371777d.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Feb%202015/2TruckwashFeb212015_zps1836c0c9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Feb%202015/2TruckwashFeb212015_zps1836c0c9.jpg.html)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: 300rag on February 22, 2015, 04:58:14 AM
Looks like you are going to have to bust out the lawnmower soon.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Bill on February 23, 2015, 02:54:46 AM
Wait wait wait.  It's already that green way up nort der?
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 23, 2015, 07:24:19 PM
Quote from: 300Rag
Looks like you are going to have to bust out the lawnmower soon.

"Mowing the lawn"....You don't have to get vulgar....(http://www.moparfins.com/forum/smileys/smiley2.gif) (http://www.moparfins.com/forum/smileys/smiley36.gif)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: 300rag on February 28, 2015, 07:32:16 AM



(http://www.moparfins.com/forum/attachments/37/0213.jpg)

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on February 28, 2015, 04:25:34 PM
Nope...Never.  That thing is a show truck.  I drive mine everyday...so it would never, nor would I ever want it to, look that nice. (http://www.moparfins.com/forum/smileys/smiley2.gif)

That is a gorgeous truck, don't get me wrong.  I love the color, and the no chrome theme on the body and trim.  But not my cup of tea. 

Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 28, 2015, 07:31:47 PM
Today was spring service time.  Air/oil/fuel filters and oil change, and grease the truck.  

Also got a low mileage head from a 95/96 Ford F700 truck...supposed to be about 25K km's.  Truck was an insurance write off and parted out, and my friend got most of the engine parts for the P-Pump motor.  It had been sitting for a few years, I bartered for it.

Fresh after delivery...These heads are definitely a 2 man job to carry!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/April%202015/PICT0059_zpsy9yowbc9.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/April%202015/PICT0059_zpsy9yowbc9.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/April%202015/PICT0061_zpsu0uouss1.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/April%202015/PICT0061_zpsu0uouss1.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/April%202015/PICT0062_zps3clqqa92.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/April%202015/PICT0062_zps3clqqa92.jpg.html)

The underside looked worse then it was.  A little bit of time spent with a wire brush and then some 120 grit sand paper cleaned it up nicely.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/April%202015/PICT0065_zpsp0akv6rg.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/April%202015/PICT0065_zpsp0akv6rg.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/April%202015/PICT0066_zps5gg43ojv.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/April%202015/PICT0066_zps5gg43ojv.jpg.html)

I really like the air intake set-up.  It is a grid heater delete spacer and a 3" air inlet horn!  

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/April%202015/PICT0067_zpsbiaggfbg.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/April%202015/PICT0067_zpsbiaggfbg.jpg.html)

Thinking of adding the grid heater delete to the crewcab from around April to Sept, then swap the grid heaters back on for the cooler seasons.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on March 29, 2015, 07:48:44 AM
Why not just leave it there and just disable it?  
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on March 31, 2015, 08:16:38 PM
Quote from: POLARACO
Why not just leave it there and just disable it?  

Just the actual heater mechanism within the housing cause a bit of an air restriction....so having an open plate could increase air flow, and perhaps grab me a little more in fuel economy? 

As you know Steve...it's the accumulation of the little things that eventually help with the increase in fuel economy. (http://www.moparfins.com/forum/smileys/smiley2.gif)


Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 03, 2015, 09:34:05 PM
Well today I swapped in a NEW Napa Master Cylinder.  I was going to get one locally here in BC, but the best warranty I could find was a 1 year only!  Just across the boarder at the US Napa I could get a new unit with a lifetime warranty!  Seemed like a no brainer to me. ;)

Gave it a coat of paint, but as other s have found the lid leaked before I even got it on the truck. :(

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/April%202015/PICT0013%20New%20NAPA%20unit_zpstaa69pjs.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/April%202015/PICT0013%20New%20NAPA%20unit_zpstaa69pjs.jpg.html)

Here you can see the reason for the leaking.  The old "Made in the USA" seal vs the new generic no name brand.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/April%202015/PICT0012%20new%20vs%20old%20cap_zpsshbwxvi2.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/April%202015/PICT0012%20new%20vs%20old%20cap_zpsshbwxvi2.jpg.html)

 I cleaned up the old seal and installed it on the new cap and so far no leaks.
Title: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on April 03, 2015, 09:46:27 PM
The other night I started obsessing over a Hydro boost conversion for my crewcab.  I then saw a craigslist ad for a 2000 cummins ram being parted out.  Several E-mails, and a phone call later had me over at the guys house pulling a hydro boost set-up!

Was a little disappointing that it was leaking out the back once I got it out and could inspect it..  So I wasn't going to take it, but he was willing to sell it at core charge value.  Figured I went 45 min out to his place I may as well return with something. ;)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/April%202015/PICT0008_zpsrjj9vfpn.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/April%202015/PICT0008_zpsrjj9vfpn.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/April%202015/PICT0011%202_zpsrfamewyb.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/April%202015/PICT0011%202_zpsrfamewyb.jpg.html)

Nice guy, he bought a nice 90 2wd 1st Gen with the insurance settlement from his 2000. We chatted diesel trucks for a bit before I headed out.  

Now to see if I can find a reseal kit for this unit, and then a "How to" on how to Re/Re it.
 
Title: Re: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 07, 2015, 12:13:34 AM
Seems as though on the forum swap we lost a couple months worth of updates on the crewcab...here is the missing posts. ;)

June 10/2015

Today I gave Patches a good cleaning...inside and out. Noticed my E-brake pedal assembly had come loose AGAIN! This is the third time in just over a year. This time it got lock nuts and washers instead of the OEM hardware. And I greased the drive train as well.

Then pulled the skid plate off because it was rattling every time I hit a decent size bump. It was the center part that rests against the tranny cross member. It was worn through the paint to make shiny metal. I cleaned everything and then added some Neoprene/foam gasket material. Should quiet it up for a while.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202015/PICT0005_zps8vz3evha.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202015/PICT0005_zps8vz3evha.jpg.html)


I also swapped out my 93 LE tailgate since the latches were starting to fail and only the RH side was actually grabbing...barely. I swapped for one of my earlier tailgates. The center brushed aluminum trim panel was missing the "Dodge Ram" emblem, so there were 3 holes visible.

So I dug through my box of misc ram emblems and made this up. I had a set of "Ram 150" emblems, so I cut off the 150. And the "Cummins Turbo Diesel" was cut off a junk set of "Power Ram 250/cummins turbo diesel" emblems. A little black paint along the edges where they were trimmed, and some 3M trim tape and voila!

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202015/PICT0010_zps7eb6rrfa.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202015/PICT0010_zps7eb6rrfa.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/June%202015/PICT0011_zpss1ofjdx0.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/June%202015/PICT0011_zpss1ofjdx0.jpg.html)

Title: Re: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 07, 2015, 12:15:56 AM
July 05/2015

Did some AC diagnosis today. Wanted to see if the AC would blow cooler with no Power Stroke Intercooler in front of the condenser. So I pulled the front of the truck apart, then stuffed an old fan in front to help blow air across the condenser.


(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202015/PICT0001_zpsxmobv1cp.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202015/PICT0001_zpsxmobv1cp.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202015/PICT0003_zpsedwoyq3f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202015/PICT0003_zpsedwoyq3f.jpg.html)


It was 37*C (approx 105*F) and with no IC in the front I was seeing about 57*F from the vents. After reassembly I ran the truck again and the temps jumped up to about 65*F.

So clearly the Intercooler is causing the efficiency of the system to drop.

Only problem I ran into was one of my intercooler boot clamps snapped.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202015/PICT0004_zpsz3466g0f.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202015/PICT0004_zpsz3466g0f.jpg.html)

Thankfully I had a spare big one from ??? That worked as a replacement.
Title: Re: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 07, 2015, 12:18:02 AM
July 06/2015

My left turn signal bulb in the dash popped on, and stayed on, while I was out getting groceries. It does this if a running light is out. Checked the truck and my lower front fender side amber light was out.

Got home and popped in a new bulb...nothing. Hmmm try another bulb...nothing. Go get test light...have power to plug so should come on. Checking out the tangs in the plug and they looked a little compressed. So grab a pick and bend them out, insert 3rd bulb and still nothing.

OK now I'm getting cheesed. So go grab a couple alligator clip jump wires. Test all three bulbs...only one was working. OK put working bulb in again, still nothing. Decided to test connectors while bulb is in socket. Had test light on the ground, and had power on one side. Then switched test light to positive, no ground coming into bulb.

OK so I probe the wire on the outside of the connector....still no ground. Now I figure it must be a bad splice or broken wire. So I start pulling the wrap off the wiring. Noticed that the front turn signal/marker bulb also used the same wires, so figured they must join somewhere and that would be where my problem was. I Got it all off all the way back to the inner fender and the big bundle of wrapped wires there...Still no splice.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/July%202015/PICT0001_zpsikggjxy5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/July%202015/PICT0001_zpsikggjxy5.jpg.html)

I then went and got my FSM and started looking at the wiring diagrams. Appeared that there was no splice in the engine compartment. I went back out and was looking at things and then noticed that the front amber bulb was burnt out as well. I thought what would be the odds that if the front signal bulb was out, that the side bulb would not work either...well after a new front bulb the side one started working....

So there ya go folks I learned something new today, it only took me an hour or so to figure it out. Lesson learned is....if you have front side marker light out, and a new bulb doesn't fix the problem...check to make sure your front marker/signal light bulb is in good shape and working properly.
Title: Re: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 07, 2015, 12:21:13 AM
Aug 17/2015

Well last night I decided to install my "new to me" turbo. It's a H1C with a 14cm exhaust housing. A generous local 1st gen owner gave it to me...Thanks Daniel!

Took about 20 minutes to pull the old turbo...then about 90 min to get the new one in and running.

Old vs new


(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Aug%202015/PICT0089_zpsdtulvfdu.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Aug%202015/PICT0089_zpsdtulvfdu.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Aug%202015/PICT0088_zpsqbwwnbru.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Aug%202015/PICT0088_zpsqbwwnbru.jpg.html)


Once the turbo was in and mounted I ran into my first problem. The 1993 turbo drain would not clear the waste gate actuator. Thankfully I had a 24V unit to use. It cleared the turbo fine, but would not quite make it to the drain tube connection off the block.

24V drain tube...

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Aug%202015/PICT0091_zpsmgctlotq.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Aug%202015/PICT0091_zpsmgctlotq.jpg.html)

Solution for it being just a bit short, and helped with proper alignment as well.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Aug%202015/PICT0092_zpszxsiq52j.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Aug%202015/PICT0092_zpszxsiq52j.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Aug%202015/PICT0093_zps6xtmuxbk.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Aug%202015/PICT0093_zps6xtmuxbk.jpg.html)

Then I had to remove my exhaust system to get everything lined up and mounted properly. That took a while. Got it running last night and went for a drive. Not as much boost as I thought it might make, but I have not touched the IP except for rotating the stock fuel pin....more fuel might help there. But it definitely spools up quicker on my shifts. Truck doesn't bog and struggle as much either.

Here is a pic of it this morning all installed....

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Aug%202015/PICT0096_zpshewqnkmg.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Aug%202015/PICT0096_zpshewqnkmg.jpg.html)

Over all I'm pretty happy with it so far.
Title: Re: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 07, 2015, 12:22:13 AM
Aug 21/2015

I replaced the coupler I used on my turbo drain last night. I had just used some old hose I had lying around....it fit so on it went. I was informed by a friend that the turbo drain does in fact have pressure, and a lot of heat. So I should be using a hose that is oil resistant, and capable of withstanding pressure, and 150*C (300*F) heat minimum.

With that crummy cheap hose I was using I was running the risk of it failing and then loosing all my oil. Motor would be cooked before all the oil pressure gauge registered the loss.

So I used the coupler off my spare 89 motor....the turbo drain, to crank case hose coupler. Clearly this part is rated for the job, so off t came, cleaned it up and installed it last night. I can now drive without having to watch my mirrors looking for oil spraying out from under the truck.
Title: Re: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Steve on September 07, 2015, 12:43:39 AM
I'm surprised you didn't retro a piece of braided hose in like the later turbos have.  They have flat flange fittings on the turbo with a flare fitting.  The 24 Valve systems have it.

Side note, I just installed a new 4" exhaust with a resonator.  The truck is quiet as a mouse now.  I also have a home grown exhaust brake I made.  Installed that too.  Can't test it until I find a suitable valve.  I need one with an air release.
Title: Re: 84 Dodge One Ton Cummins crewcab conversion....
Post by: Brian on September 14, 2015, 12:01:19 AM
I spent the day selling at a local old car swap meet...one of the last of the year for this area.  Also brought my 48 Desoto down to sell as well.

Loaded up and ready to go yesterday evening.  My friend, and neighbor went down too with some GM stuff...(That's his 63 Impala) We were down at the swap meet for 6am this morning.

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Sept%202015/PICT0015_zps5ypfcvfo.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Sept%202015/PICT0015_zps5ypfcvfo.jpg.html)

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Sept%202015/PICT0017_zpsj5wpmhlt.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Sept%202015/PICT0017_zpsj5wpmhlt.jpg.html)

Set-up and selling. 

(http://i697.photobucket.com/albums/vv340/thrashingcows/84%20Crewcab/Sept%202015/PICT0018_zps6z5ufwg5.jpg) (http://s697.photobucket.com/user/thrashingcows/media/84%20Crewcab/Sept%202015/PICT0018_zps6z5ufwg5.jpg.html)

This was the first swap meet I've ever sold at and I sold a lot of stuff!  Not many "Mopar only" guys at most swap meets.;)