I currently own a '92 w250 5spd reg cab. I am considering the following conversion:

First, '97 cummins motor
Second, 6 speed transmission
Third, 2500 to 3500 conversion

I have read quite a few threads on the g360-nv5600 conversion, but usually it is on a 1st gen motor. Will the process be somewhat the same for a '97 motor, as in, how to use the nv4500-nv5600 conversion guidelines and than wrangle the thing beneath my 1st gen truck? Has anyone done this swap?

I also read the arrowcraft conversion (2500 to 3500) was hard on the bearings and not a good solution to putting a true dually axle underneath the rear. Any input on that?

Sidenote: I am considering stacks....how will i construct a exhaust that adapts to the second gen motor but clears the 1st gen t-case and so on underneath the truck. Will stacks be too loud on a reg cab truck fairly well insulated?

Any place i can find 1st gen interior pieces such as the bucket seat set-up?

Thanks to all for the assistance. I know i have been asking many questions on this forum, but if everything works out reasonably well, i am about to spend a good deal of money on my truck....makes me quite nervous and i was hoping to get most of this info in one conscise thread, plus answer a few unanswered questions. Thanks again. redwake

 

I wouldn't do a 6 speed. They are notoriously difficult to shift and rebuild parts have gotten very scarce and expensive. I'd run the Getrag or an NV4500.

The conversion is the same, you need the same pieces to make everything fit up.

A '97 motor will bolt to your exhaust. If you are concerned about noise with stacks, get a 180 degree muffler for a medium duty truck, it has the inlet and outlet on the same end and will hang where the stocker did.

If you want 1st gen buckets (and I heartily recommend them) it's time to hit the junkyards. Ramchargers are a good source.

 

A friend of mine had a 91.5 W250 with a single stack and no muffler when he got it. It was just about unbearable inside the cab. He ended up ditching the flatbed and the stack, and putting on a pickup bed and a full exhaust.