Ok guys, back on the subject at hand.
I have no idea if the Cummins ISB will physically fit in an 02 GM. There may be some adapter available (try some place like Advanced Adapters) to mate the ISB to the GM Allison tranny.
A valid queston would be, why not dump the Allison and replace it with a (well built) Dodge tranny?

The concerns I would have would be related to things as:
1) Wieght of the ISB and the wieght limit on the GM IFS.
2) Wiring/electircal/computer system. Getting GM's electronics to mate with the ISB's electronics.
3) The cost involved in getting all the adapters needed to make it work.... and work right.

With enough money, you can probably stuff an ISB into a AMC Pacer.
If it has to be GM and your set on spending that kind of money to fit it with an ISB, you might consider restoring an older GM truck that has less/no electronics to deal with and is equiped with a Dana 60 front axle.

Just some ideas.

Rich

 

 

Fix the truck and trade it in on a dodge.

 

It is rarely worth doing an engine swap in a newer truck such as this, particuraly with all the electronics involved. The tread starter seems to be avoiding details, such as what actually "blew up" etc. The Dmax is a soild unit, the Chevy truck is a good vechile too. Just calling them "junk" helps nothing, and if I may say it, dimishes credibility.

I would reccommend repairing the truck, and if your father (as it's his truck, right?) wants a Cummins, head down and purchase one.

 

"It is rarely worth doing an engine swap in a newer truck such as this, particuraly with all the electronics involved."

And why would that be ? The electronics involved are not difficult nor expensive. And when you get done, you've got an awesome truck.

Conversely, I sometimes wonder why people chose older/almost worn out trucks for their swap recipients. Especially when the prices for newer used trucks are very reasonable, especially if you can find one with a gasser or blown diesel.

I am very happy with my swap and I wouldn't trade my truck for any other. It is exactly what I desire in a truck and it was inexpensive to obtain as well. Swapping is a lot cheaper than trading for a new truck.

My swap took 8 days and about $4500. In the process of doing the swap, I got a new engine, turbo, exhaust system, alternator, A/C compressor, clutch, power steering pump, fan clutch, water pump, rad hoses, air filter, U joints, starter, etc.

I've now got 81,000 miles on my '99 and it is pretty much like new. The body/frame/interior are in excellent shape. I see no reason why I won't get another 80,000 to 160,000 miles from this truck with very few problems. Much fewer problems than buying a new Ford with a 6L, for example.

I highly recommend swapping a Cummins into a newer truck. I think it is an excellent thing to do. The Cummins, especially the 3rd gens, are very sweet engines.

A good place to discuss swaps is at www.cummins-conversion.com

There was an article at TDR about a guy swapping an Allison onto his Dodge Cummins. I'd have a look at how he did it. I think his Allison had an SAE bellhousing, ie motorhome model. One could machine an adapter plate to mate a Cummins to your Chev Allison. I machined the adapter plate for my swap. It is a pretty advanced thing to do, but definitely possible.

You might also consider swapping your Allison for a ZF6. In my thinking, a ZF6 is a perfect match to the 3rd gen Cummins. I am not fond of automatics behind diesels.

One more thing: your Chev might be a bit short in the engine compartment. The Ford SDs work well because they are designed to fit the V10, which is a long engine. My truck was 38 inches between the back of the radiator and the firewall. And my 3rd gen Cummins fit that perfectly. Any shorter and there would have been issues.

 

What, you didn't know all the roads in Indiana are downhill and there's a constant 30mph tail wind?

All kidding aside if your dad does end up doing this swap a detailed right up thread here on DTR would be excellent!

 

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I've gotten as high as 27 MPG highway.
But I can't keep my foot out of it in town. I like watching ricers try to catch up when I torque off a light in front of them
Not a real race, but no one who puts a fart muffler on a wanna be saki rocket likes to see the back end of a rattly old truck

 

I have seen some 12V engines come close to 28-29mpg CDN but if GM(supersuzzie) and Dodge are generating these MPG figures I will definitely dump my inferior 24V engine. Engine swap issue #1 the Allison 1000 series transmission is only rated for 550ft/lb torque approx. #2 electronics are programmable using Cummins electronics with Allison electronics is very likely as they already have some packages in production- this process is a lot easier than making mechanical components physically fit sometimes. GM IFS is noted as the weak link in their trucks adding excessive weight would be a serious issue but there is a guy in Sylvan Lake Alberta who has a 12V in a 1990 Chev 1 ton reg cab 4X4. #3 tell some people it cant be done and they will make a point of making it happen, at what cost- they dont care it is a life challenge. For Sale 1- W900 Kenworth 3406 Cat 13 speed tandem, guarranteed 22.6 mpg CDN, 4 wheel drive with power divider in will go anywhere ???? PK

 

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has anyone seen my boots, it got too deep in here and ive ruined my tennis shoes already

i have 115hp injectors, a 40-120hp adjustable chip, 4" exhaust, gauges, fuel system, intake, and much more and i got a hand calculated 13.3 mpg on my last tank...thats what happens when all that black comes out the stacks up top. i went on a trip a few weeks ago, kept the comp down on setting 3, kept my foot out of it and drove a steady 70mph and only got 18mpg unloaded

this kid is so full of it i dunno whether to laugh, or feel bad that he has a rough life coming up. good luck with the swap, its easy, me and my buddy Leroy did a couple of these swaps already, takes about 4 hours or so, and the cummins with a allison behind it will runs 13's without any other performance mods...great tranny and motor combo

 

There is your problem right there. Next time buy a truck without problems!

30mpg-US? Yeah, and my truck runs off tap water.