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4BT swap into 99 sport 1500

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Old 03-03-2014, 07:36 AM
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Talking 4BT swap into 99 sport 1500

got started on this project yesterday, pulled the 360 and the 46re out, took me and a friend less than 1 hr from a complete driving truck to engine and trans sitting on the asphalt, then we hoisted up the 4bt, swaped out the rear adapter plates and bolted a 47re to the back and set it in.

so far we have a few fails and a few wins.... the original driveshaft and crossmember are a perfect fit for the 47re, (this is all 2wd stuff), thats a huge plus, as well as the 6bt vacuum and power steering pumps and the 6bt starter all fit in there, i have to do a little clearencing on the PS pump reservoir as it contacts the injection pump, but its minimal.... the bad news... the factory turbo interferes with the firewall due to the exhaust manifold position, some repositioning of the manifold may work or i will modify a 6bt manifold to work, also wanted to use the 6bt engine mounts but that is a no go with the 6bt pumps, starter, and a/c pump in there, so the factory frame mounts need to come out and i will fab something off the front of the engine



day i bought the running/driving truck for $800



changed tires, wheels, and bumpers



1hr into the tear down



and the 4bt/47re sitting in there



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98-12v cummins converted from v10,cammed,nv4500,compound turbos,SB3600DD,heavily modified
07 red mega cab long bed,cummins 5.9,G56,mygig,southbend, smarty, more... 99 1500 4bt
The woman's-02 cummins,3500 dually,NV5600,lifted,some added fuel, and 2013 dart 2.0 6spd

Last edited by dodgetrucker75; 03-03-2014 at 08:47 AM..
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  #2  
Old 03-03-2014, 09:27 AM
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Looks good. Lots of people talk about stuff like this and its good to actually see someone go through with it!

You work fast, and I like folgers coffee too. LOL
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Old 03-03-2014, 12:49 PM
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Looks good. Lots of people talk about stuff like this and its good to actually see someone go through with it!

You work fast, and I like folgers coffee too. LOL
i know what ya mean, there always a lot of "i want too" talk with out a whole lot of doing anythig....

folgers is awsome, plus you end up with a handy sealable bolt bin when you are done
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98-12v cummins converted from v10,cammed,nv4500,compound turbos,SB3600DD,heavily modified
07 red mega cab long bed,cummins 5.9,G56,mygig,southbend, smarty, more... 99 1500 4bt
The woman's-02 cummins,3500 dually,NV5600,lifted,some added fuel, and 2013 dart 2.0 6spd
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Old 03-03-2014, 02:05 PM
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I love it! Ive been doing some research on this myself right before coming here. Im thinking it would be perfect for my 1500 and I can go manual trans at the same time. Keep us updated. I have a few of those folgers parts bins too.
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Old 03-03-2014, 02:49 PM
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I love it! Ive been doing some research on this myself right before coming here. Im thinking it would be perfect for my 1500 and I can go manual trans at the same time. Keep us updated. I have a few of those folgers parts bins too.
a manual was my very first choice, but found the auto truck so cheap, and also found cheap, complete and rebuilt (says the CL poster) 47re, so i figured why not, i hate autos with a passion, but all 6 of my vehicals are manual, except for the 1948 dodge with a 12v cummins also has a built auto, but the truck is in the process of being built at the moment too, an auto might be a nice change once in a while, but i am hard on them and they tend not to last very long at all when i have control of the skinny pedal
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98-12v cummins converted from v10,cammed,nv4500,compound turbos,SB3600DD,heavily modified
07 red mega cab long bed,cummins 5.9,G56,mygig,southbend, smarty, more... 99 1500 4bt
The woman's-02 cummins,3500 dually,NV5600,lifted,some added fuel, and 2013 dart 2.0 6spd
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Old 03-10-2014, 02:15 PM
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got a little more done over the weekend, but had to do a quick shut down and clean up of the project due to weather, so dont have any pics yet, maby get some tonight

got the shift linkage figured out, had to you the cross shaft linkage(frame to trans) and the arm from the cross shaft to the trans, from the 47re truck.... but had to use the trans bracket from the 46re bolted to the 47 for everything to align correctly, guessing thats part of the difference of the 1500-2500 frames, as i believe the 2500 frame is a bit taller, and the nuetral/reverse switch had a different plug but the switch from the 46 went right into the 47 and all trans electrical pluged in ( my 47re is from a 97 2500)

got all the sepentine system off the engine witch was a industrial and non a/c setup, and installed the dodge 6bt system, witch changes the coolant necks, and gives mounts for the a/c compressor, and the mopar altinator, but ran into yet another issue, the industrial fan hub is different from the dodge hub and the pully contacts the dodge upper water neck, so i have to locate the dodge fan hub witch i believe i already have,

other than that, i just have to pull the engine one more time, remove the factory engine mounts from the frame, install the oil pan and bolt the engine back up one last time to the trans and make the new engine mounts, hook up all the nick nacks and with any luck it will be driveable in a week or two, then it will be time for the twin turbo build, and some performance tuning on the fuel system already got all the stuff to do that too, just wana get it to run and drive before i start to play with it
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98-12v cummins converted from v10,cammed,nv4500,compound turbos,SB3600DD,heavily modified
07 red mega cab long bed,cummins 5.9,G56,mygig,southbend, smarty, more... 99 1500 4bt
The woman's-02 cummins,3500 dually,NV5600,lifted,some added fuel, and 2013 dart 2.0 6spd
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Old 03-12-2014, 12:02 AM
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Here's a few photos

Here you can see the dodge serpentine system minus the fan hub and damper, you can see on the left how close the a/c mount is to the frame, but its not an issue yet



Here is the reason its sitting so far to the passenger side, removing the factory engine mounts from the frame should free up all the room I need



Here is a bad shot of the passenger side mount clearance as it sits



And I removed the water to air after cooler, so I made this plate, next step will be to cut a hole and weld up a pipe to mate up to the factory 2nd gen ram intercooler

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98-12v cummins converted from v10,cammed,nv4500,compound turbos,SB3600DD,heavily modified
07 red mega cab long bed,cummins 5.9,G56,mygig,southbend, smarty, more... 99 1500 4bt
The woman's-02 cummins,3500 dually,NV5600,lifted,some added fuel, and 2013 dart 2.0 6spd
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  #8  
Old 03-12-2014, 10:41 AM
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Lookin' good.
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Old 03-17-2014, 03:05 PM
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got some more done this weekend

pulled the engine back out and fixed the infamous "killer dowl pin" as well as tightened all bolts in side the timong cover



got an 1 1/4 freeze plug to plug the original oil fill tube in the side of the block



removed most of the factory frame engine mounts



cut down a factory 6bt exhaust manifold





and did a little porting





was able to bolt up the gas a/c compressor, and with some bending of the lines, the gas a/c lines will work, the front 2 compressor bolts lined up, but the back ones did not, however there were provisions in the corect location, just had to drill them out and remove a small piece with the die grinder inbetween the holes

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98-12v cummins converted from v10,cammed,nv4500,compound turbos,SB3600DD,heavily modified
07 red mega cab long bed,cummins 5.9,G56,mygig,southbend, smarty, more... 99 1500 4bt
The woman's-02 cummins,3500 dually,NV5600,lifted,some added fuel, and 2013 dart 2.0 6spd
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Old 03-18-2014, 12:06 PM
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got the engine mounted, tho i am not very happy with the brackets, but with the limited tooling i have in the drive way, they will have to work for now



a shot of the turbo all mounted up, couldnt have worked out any better, and its in the exact position as a twin turbo ram so my options for my twin mounting are pretty much endless



got the the aftercooler and condenser in there as well as the gas radiator and shroud, the gas radiator actually fits very nice in there, and got all the heater hoses hooked up as well as 80% or so of the electrical done



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98-12v cummins converted from v10,cammed,nv4500,compound turbos,SB3600DD,heavily modified
07 red mega cab long bed,cummins 5.9,G56,mygig,southbend, smarty, more... 99 1500 4bt
The woman's-02 cummins,3500 dually,NV5600,lifted,some added fuel, and 2013 dart 2.0 6spd
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Old 03-18-2014, 12:09 PM
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Coming together pretty good. How so before you crank it up?
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Old 03-18-2014, 12:15 PM
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Coming together pretty good. How so before you crank it up?
hopefully in the next week or so, i mainly just have to locate a second ram starter, i have a 1st gen starter but discovered yesterday that they are different, other than that, all i need to do is put fluid in the engine and trans, run the trans cooler and fuel lines, and finish installing the bellhousing bolts and converter bolts then i can crack it off
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98-12v cummins converted from v10,cammed,nv4500,compound turbos,SB3600DD,heavily modified
07 red mega cab long bed,cummins 5.9,G56,mygig,southbend, smarty, more... 99 1500 4bt
The woman's-02 cummins,3500 dually,NV5600,lifted,some added fuel, and 2013 dart 2.0 6spd
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Old 03-18-2014, 12:20 PM
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All the tedious little stuff that goes along with an engine swap. Seems that is what takes the most time.
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Old 03-18-2014, 06:34 PM
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Originally Posted by dodgetrucker75 View Post
got the engine mounted,


a shot of the turbo all mounted up, couldnt have worked out any better, and its in the exact position as a twin turbo ram so my options for my twin mounting are pretty much endless
Looking good!

With the turbo in that location will you be able to run a factory (or direct replacement) exhaust? I was considering using an aftermarket Ram 2500 6bt exhaust to run behind a 4bt. It's just a matter of getting the turbo in the right spot.
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Old 03-19-2014, 10:41 AM
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Looking good!

With the turbo in that location will you be able to run a factory (or direct replacement) exhaust? I was considering using an aftermarket Ram 2500 6bt exhaust to run behind a 4bt. It's just a matter of getting the turbo in the right spot.

thanks! if you ran the turbo like this as a single, the entire 6bt exhaust system would work with just a slight modification to the down pipe (just make it longer), as the manifold is upside down compared to the factory 6bt, but in all twin turbo applications, the manifold is fliped just like this one, and just about any twin turbo system will bolt up, (for the most part) even the exhaust, but im going to build my own twin piping, on a side note... on good ol ebay, you can get an entire 4'' turbo back exhaust for a ram for $230, and a 5'' for $340
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98-12v cummins converted from v10,cammed,nv4500,compound turbos,SB3600DD,heavily modified
07 red mega cab long bed,cummins 5.9,G56,mygig,southbend, smarty, more... 99 1500 4bt
The woman's-02 cummins,3500 dually,NV5600,lifted,some added fuel, and 2013 dart 2.0 6spd
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Old 03-19-2014, 06:00 PM
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getting closer....

got all of the ecectrical done and tested last night except for extending and connecting the a/c clutch and pressure sensor connectors,

got the shift linkage, throttle, cruise, and TV cables all mounted up, but throttle bracket may require further modification as the injection pump as a very short and stiff throw, i think i might remove the and raise the bracket and extend the lever on the pump for a longer throw and less pedal effort,

all of the engine and trans mounts and hardware are in and tightened

still have quite a few small "loose ends" to tie up, but im picking away at them every chance i get before and after work, was hoping to drive it this weekend but due to an almost impossible schedual this week, i may have to postpone that thought for one more week
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98-12v cummins converted from v10,cammed,nv4500,compound turbos,SB3600DD,heavily modified
07 red mega cab long bed,cummins 5.9,G56,mygig,southbend, smarty, more... 99 1500 4bt
The woman's-02 cummins,3500 dually,NV5600,lifted,some added fuel, and 2013 dart 2.0 6spd
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Old 03-19-2014, 10:53 PM
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Thanks for the information.

Keep after it. You'll be driving before you know it.
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Old 03-19-2014, 11:49 PM
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Any videos by chance, after she's all done? BTW sweet build, I'm always interested in people doing 4bt swaps. I wouldn't mind doing one myself but I don't have the time or resources to do one. So it's better off a dream.
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Old 03-20-2014, 10:54 AM
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Any videos by chance, after she's all done? BTW sweet build, I'm always interested in people doing 4bt swaps. I wouldn't mind doing one myself but I don't have the time or resources to do one. So it's better off a dream.
you bet! and thanks

did a little more playing around last night, got the gauge pod mounted (pillar) got the intercooler and condenser mounted and all a/c lines connected, got the radiator all in position and the hoses figured out, was just about done with adjusting the fenders and the hood when my dumb a$$ shut the hood.... and remembered i didnt hook up the release cable, so that is the start of my project tonight, trying to get the hood open again
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98-12v cummins converted from v10,cammed,nv4500,compound turbos,SB3600DD,heavily modified
07 red mega cab long bed,cummins 5.9,G56,mygig,southbend, smarty, more... 99 1500 4bt
The woman's-02 cummins,3500 dually,NV5600,lifted,some added fuel, and 2013 dart 2.0 6spd
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Old 03-20-2014, 11:12 AM
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You can go up through the bumper air slots (with normal sized arms) and reach the latch. Been there, done that. Worse case scenario...just pull the bumper off and maybe the grill.
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Old 03-20-2014, 11:12 AM
 
 
 
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