OK... Pacesetter LT's fitted.

Being a Reg Cab SB, there wasn't room I hoped for the Cat, so that was scratched.
After the Y-pipe I just have a 5"x8"x24" c-c Magnaflow muffler and tail pipe (w/4" tip).
Put the DS O2 in just before the muffler... so far, no codes, but will do the the plug saver trick if needed.

The driver-side header was a fitment issue.
Some had said the starter didn't need pulling (despite that being in the instructions) but not only did I have to pull the starter, but I had to undo the engine mount and jack it up a couple of inches to get the header in.
Once in, there is very little (~¼") clearance to the frame rail... lucky the engine torques the other direction and I don't get a hit.
Where I did have interference was the front tail-shaft balance weight hitting the collector... a little heat and leverage took care of this.

Continuing on the driver-side, the Y-pipe clears the universal on the front of the transfer-case by ~½", but interfered with a lobe on the side of the transfer-case (flat on the bottom, likely for install support?)... this was cut off to clear.

So, it's all in and nicely secured... time to test drive.
Sound wise, I wasn't looking for loud, but merely a deeper throaty tone... I got exactly what I wanted, though just a little louder... a great V8 sound.
There seems to be more power, but........

Now, for the down side... if accelerating anything more than mildly, the universal on the front of the transfer-case hits the Y-pipe.
This only happens at lower speeds when accelerating harder... at higher speed it doesn't happen no matter how hard you accelerate, so it's a torquing issue.

I don't want to collapse the pipe in this area to gain clearance if I don't have to (it would be a longer length and greater amount than I had to on the collector).

What are your thoughts on why I've had the fitment issues that others have not?

Any suggestions on how to gain the clearance needed, or lessen the movement under load?

TiA,

 

These are what I went with to control motor slop in the junk motor mounts. They should solve your problem. Would it help to clock the xcase down at all?

1994-02 Motor Mount Insert Set - Ram 2500 / 3500 2 & 4WD 5.9L Cummins Diesel 5.1114

http://www.energysuspensionparts.com...sp?prod=5.1114

Edit to add pix of said motor mount insert.

 

Check the rear trans mount as well. Going to a poly mount probably wouldn't hurt any back there.

Merc's idea is an excellent one. Question though: Did you get any more 'vibration feel' from the harder mounts?

 

I have yet to find a poly trany mount, I looked but not that hard. Find one let me know as I will get one asap.

Yes you will feel more of the motors harmonics through out the truck using these mounts, but its very minor. After a week you get used to it.

 

You are quite right. No one seems to make them...... Not even the major manufacturers.

 

So long as the engine's running smooth, "feeling it" I don't think is a problem... and may even be an advantage in disguise when it's not.

I take it the 1500 gas mounts are the same is the 2500 diesel mounts?

 

I think ALL the motor mounts are pretty much the same.

 

Then I'll give this a try and see how much it helps.

Seeing that mount picture reminds me... the DS heat shield got damaged during install, and is now floppy, so at certain RPM's it abbreviates against the mount, making a tinny noise.
There seems to be much more distance between the header and the mount than there was between the stock manifold and mount... I'm thinking I could do away with the shield with no ill effect.

 

FYI; From Amazon...
(Black) $40.76
(Red) $43.15
Free shipping for Prime members.

 

Pic of the heatsheild in question? I don't think my truck even has one.