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4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

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  • 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

    4BT Cummins Turbo Diesel in an 05 Silverado

    I finally started driving my truck and thought I would show off a little and give the details of my build. I did this engine swap so I could have a full size truck that gets great fuel mileage instead of driving some little crappy compact car. I haven’t driven this truck enough yet to check the mileage but I will report back soon. I really did the swap because I thought it would be pretty cool but I use the mileage thing to justify it.

    I started with a 2005 regular cab, short bed, two wheel drive, Silverado. It originally had a 4.3 V6 with a manual tranny.

    Motor: 3.9L 4 cylinder Cummins Diesel removed from a Frito-Lay step van and originally had a turbo 400 tranny bolted to it. Rated at 105hp and I’m not sure of the torque numbers. It fits in the engine bay pretty nicely. I used hydraulic motor mounts out of the step van. I had to fabricate the motor mount brackets and the cross member under the motor for oil pan clearance. I used the oil pressure sensor and the temperature sensors from the V6. I also used the alternator from the V6 with a custom bracket. I used the starter from the Dodge but wired it from the fuse box instead of letting it go through the computer. The computer would only let the starter crank for a few seconds and shut-off so I bypassed it. The biggest problem I ran into was finding a good wire to use for the fuel pump shut-off solenoid. You need a keyed on power wire to it. I couldn’t get the thing to start and couldn’t figure out why. I made a real idiot mistake by using a wire that was on when the key was on but didn’t realize it shut back off when the key was turned to start mode (these late model trucks shut off a lot of electrical things to conserve the power for the starter). I also added an intake grid heater off of a dodge. These Cummins motors use these instead of glow plugs. I made my own plates for the top and bottom of this and used the dodge relays to power it. I modified a factory fog light switch by putting a momentary switch inside of it to turn the relays on. This way, when it’s cold, I hold the fog light switch down for a few seconds before I start it.







    Tranny: NV4500 5 speed manual from a 1994 1-ton Dodge along with the flywheel and adapter plate. The truck originally had a NV3500 that I figured wouldn’t hold up to the torque of the diesel. I had to make a tranny cross member to fit the larger tranny. The speed sensors (VSS) between the Dodge and the Chevy were too different for a simple signal converter so I had to make a reluctor wheel for the VSS to read. The chevy VSS reads a 40 tooth gear in the original tranny. My dodge tranny had a harmonic balancer on the slip yoke so I was able to mill 40 ¼” slots in the balancer and made a bracket to hold the sensor close to it. This worked perfectly. The next problem was the slave cylinder. The NV3500 had a small internal slave and the NV4500 has a large external slave. I wanted to use the original clutch master cylinder because the mounting of it and the clutch pedal are kinda complex and wouldn’t be easy to swap out with anything other than a larger one from a Duramax truck and they are too expensive. I ended up finding a smaller slave cylinder to match the volume of my master. I used one from a 1990 half-ton chevy. It needed a lot of modifying to make it fit this tranny but after cutting the flange, drilling some holes, and re-tapping the fitting hole for pipe threads and it worked great. I cut the end off of the factory braided hydraulic line and added a compression style fitting that had pipe threads. I had to use the dodge shifter but cut the lever off and welded the chevy lever to it so my interior looks completely stock.







    As I mentioned, I just started driving it but I love it! It runs great. Only 105hp (well the pump is turned up a little) but the torque is awesome. It will smoke the tires in 2nd gear and bark them in 3rd. It doesn’t vibrate bad at all like other 4BT owners have complained about. It is a little loud compared to the gas motor but I don’t mind it and I don’t think it is any worse than an old 12 valve Dodge. My next plans are getting the A/C compressor bolted to it (using the original one from the V6) and adding an intercooler.
    Daily - 2005 1/2-ton 2wd Silverado with a Cummins 4BT & NV4500
    Farm - 2003 1-ton 4x4 Dodge Ram with a Cummins 6BT & NV5600
    Toy - 1991 Camaro with full air ride, a built Vortec 350, & T56


    MY PICTURES

  • #2
    Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

    that looks sweet, definitely unique!!!! Im gonna check back for mileage updates and possible power upgrades?


    05 Gmc 2500hd, CCSB, loaded, bully dog programmer set on performance, billet grille, drop in afe filter, swiss cheese airbox, MBRP exhaust, kodiak mp, moron behind the wheel

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    • #3
      Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

      I think even a intake and exhaust upgrade would be enough, you probably won't want a smoker! That looks a stock intake box off the v6 correct? Still running the electric fan?


      05 Gmc 2500hd, CCSB, loaded, bully dog programmer set on performance, billet grille, drop in afe filter, swiss cheese airbox, MBRP exhaust, kodiak mp, moron behind the wheel

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      • #4
        Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

        Subscribed for results

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        • #5
          Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

          thats what im in the process of doing with an 0bs, wasnt sure of what tranny to do, will also be a sfa, as it is a 2wd chassis i am starting with, so I am going to do a 14b, and d60.



          LAND OF THE OVERWORKED,HOME OF THE UNDERPAID
          Originally posted by Silverado_13
          I will call your chill the f*ck out and raise you one shut the f*ck up. :aniteef:

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          • #6
            Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

            great job on the swap! looks really clean. should be interesting to see what kind of milage you get.

            03 GMC 2500 HD CCSB duramax, 6" full traction lift. 37/13.5/20 Toyo Open Country MT's, ATS E-Power tuner, AEM intake, Stage 3 allison
            452 RWHP/755 TQ verified on superflo dyno, 7/19/08 (ATS level 10) :fsg:

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            • #7
              Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

              dude you the man. that looks sweet. i'm going to putting a 12v in a 99 1500 too and am trying to figure out ideas to run the stock cluster. i like the ballancer idea you did.

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              • #8
                Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

                Hey man nice build! I'm looking for a 5.9l cummins turbo for an old international truck i have. Where did you find this one and about how much do they run.

                1998 k1500/5.7/3.73/Mickey Thompson MTZ/Moto Metal 951/14b sf/Wheatley tune
                1967 International 1500B/16,000 GVW/hydraulic bed/1 owner

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                • #9
                  Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

                  Nice!

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                  • #10
                    Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

                    Thanks guys.



                    Originally posted by 1994Gmcsierra71
                    I think even a intake and exhaust upgrade would be enough, you probably won't want a smoker! That looks a stock intake box off the v6 correct? Still running the electric fan?
                    I am using the stock muffler because I didn't know how loud it would be. I'm considering removing it but not sure. The air filter is the stock one from the V6 so I'll eventually change that. The electric fans are the original ones, still on, and work fin.

                    dude you the man. that looks sweet. i'm going to putting a 12v in a 99 1500 too and am trying to figure out ideas to run the stock cluster. i like the ballancer idea you did.
                    I'm running the stock cluster and all the gauges work except the tach and I'm planning on getting it to work with a Dakota Digital DSL-2. Just use your original sensors on the 12v and they will work.

                    Hey man nice build! I'm looking for a 5.9l cummins turbo for an old international truck i have. Where did you find this one and about how much do they run.
                    I paid $2700 for a complete step van to part out. I know some people have gotten them a lot cheaper but this one was close to home. If you are looking for a 5.9 then check the junk yards or for old Dodges with rough bodies so you can buy the whole truck cheap.
                    If anyone is interested in a good low mile (less than 40k miles) 12 valve, my buddy has one for sale. I think he is asking $4000. He pulled it from a wrecked truck to do a Superduty Ford swap and changed his mind. PM me if interested.
                    Last edited by VortecZ; 03-11-2009, 05:53 PM.
                    Daily - 2005 1/2-ton 2wd Silverado with a Cummins 4BT & NV4500
                    Farm - 2003 1-ton 4x4 Dodge Ram with a Cummins 6BT & NV5600
                    Toy - 1991 Camaro with full air ride, a built Vortec 350, & T56


                    MY PICTURES

                    Comment


                    • #11
                      Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

                      amazing i am about to start the same swap...thanks for all the info...
                      Fatkid Racing...
                      02 rcsb 4.3 5sp 20" daytons with 255/45 toyo proxes, no cats with cherry bomb chambered muffler, 4/6 drop ,HD hood and Grille, hid's ,anzo taillights ....
                      http://www.ohiofullsize.com

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                      • #12
                        Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

                        $4000 for a 12 valve? yikes.

                        We can't sell ours for $1300 ... we have a spare

                        Yea the 4bt vans are catching on now and everyone wants a 4b.. seems like the engines themselves go for $2000. Get the alum van and pull the motor and scrap the van.

                        Need more info on tweaking the pump PM me or join some forums :).... Me and my dad are masters of the VE.
                        Currently-
                        -91 RCLB C1500 silverado 4.3L 5 speed GU4 G80 beater truck
                        -91 Dodge 350 4x4 12v Cummins/5spd 384hp/802tq


                        SOLD and missed-- 91 RCSB GMC, restored Black on black, 2/4 drop, 17x9 Torq thrusts, built 350tbi, 5 speed w/hurst shifter, 3.42 G80--- Over 400,000 miles on body

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                        • #13
                          Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

                          Originally posted by crossy'son
                          Need more info on tweaking the pump PM me or join some forums :).... Me and my dad are masters of the VE.

                          Thanks, I'm more of a P-pump man but I plan on learning more about the VE myself. This one was a little wore out so I sent it to Scheid Diesel to get rebuilt. They updated it, did all their little tricks to it, and removed all the cold-start crap off the side of it. It should be good for a while. I think they may have turned it up a little too much because I get some pretty good black smoke. It should help when I get the intercooler on it.
                          Daily - 2005 1/2-ton 2wd Silverado with a Cummins 4BT & NV4500
                          Farm - 2003 1-ton 4x4 Dodge Ram with a Cummins 6BT & NV5600
                          Toy - 1991 Camaro with full air ride, a built Vortec 350, & T56


                          MY PICTURES

                          Comment


                          • #14
                            Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

                            Originally posted by VortecZ
                            Thanks guys.

                            If anyone is interested in a good low mile (less than 40k miles) 12 valve, my buddy has one for sale. I think he is asking $4000. He pulled it from a wrecked truck to do a Superduty Ford swap and changed his mind. PM me if interested.

                            by far, the greatest combo that SHOULD have been made.

                            damn ford for being loyal to international all those years...
                            '94 Z-71
                            H/C/I/LTs
                            '02 z-71
                            Stainless LT's/ORY, 285's
                            '95 Formula
                            364ci, 3spd, 3.73's


                            all, Tuned By:
                            Bluecat
                            KYHORSEPOWER.COM

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                            • #15
                              Re: 4BT Cummins Turbo Diesel in an 05 Silverado (with pictures!)

                              That thing is awesome

                              Transgo HD2 | Magnaflow DI/DO | CAI | BlackBear Tune| Dual Optima Red Tops: 2000 Cold Craking Amps | Denali Projectors |

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