I currently have a 1999 2500 4x4 with a 5 speed stick. It has close to 225K on the motor and it's beginning to show its age. (Plenum gasket, valve seals, possible ring issues). I've worked hard to keep the rust monsters at bay, so the body and frame are in better than typical shape.

I have an opportunity to pick up a 2002 2500 with only 63K on it that the body has literally rusted off it (plow truck) for very short money. My hope is to strip the truck and sell off the axles, rebuilt transmission and the good bed and keep the engine for my truck.

My question is how easy would the swap be and are there any particular issues that I need to be aware and prepared for? I am especially looking for advise on mating up the 1999 electronic systems with the 2002 engine and making sure the new engine will mate with my 5 speed (that I love).

I am hoping someone out there has done this swap before and can help me benefit from their experience. Any advise and direction would be greatly appreciated.

Thanks in advance!

 

is the 2002 an auto?

 

Ham Bone - YES, the newer engine has an automatic trans and my truck has a 5 speed.

 

Pretty sure the 02 engine will drop right in and things will plug up. But you could always just swap your sensors from the 99 onto the newer engine. Many have done that when going from obd2 to obd1. 97-up to 94-96. But you're just going from 99-02.

There may be minor diffferences. but nothing drastic.

You will need to put the flywheel on your old engine from your new one obviously. The 02 will just have a little flexplate.

Let me know if that 02 has a central axle disconnect on the front axle. I'm curious.

You are talking about 5.9 gassers correct?

 

Thanks for the info HB. Yes, they are both 5.9 gas engines. I'm gonna put in a new clutch while I have everything apart, but I figured that it would be a reasonably "easy" swap (easy being a relative word). I'm hoping to do it over a long weekend, once I get the '02 engine out, cleaned up and the plenum fixed.

Can I use my original ECM or do I need to pull the ECM from the '02

Thanks for the help. I'm planning to document the swap and will post it here once complete.

 

Don't forget the pilot bushing. Goes in the end of the crankshaft.

 

oh yeah definitely dont forget that lol

you should be fine using your current ecm. especially if you just reuse your old sensors. the new ecm would be whining for an auto and throw all kinds of codes cuz its not getting any data from things it thinks should be there.


i would definitely freshen up the new engine. maybe do a comp test and put a mech oil gauge on it before your rip it out. make sure you arent just gonna be back in the same situation a few thousand miles down the road. be sure to check the plenum. no easier time to fix that when its out of the truckk.

imo these engines last better if they have been worked hard so the plow engine will probabbly be fine. but theres no sense in just going blindly into a project when it takes less than an hour to see what shape that 360 is in.

 

all the sensors will be the same. only thing you will have to worry about is the injectors. you need to swap them. 99 injectors have different connectors than the 00, and up injectors. you will also need to pull the crank sensor from your current truck and swap it over, as the crank sensors for autos, and manuals are different.

make sure you pull the crank sensor before you pull the motor!

good luck sir!

 

Redneck, that good to know and great advise. Thanks! I was planning on doing the plenum while the new engine is out and on the stand. I might also put a whole new set of injectors in while they are easily accessible.

Taking out the crank sensor SUX, but I understand that they usually get damaged when people pull the engine. I definitely plan to replace that with new while I have the space to work with.

Any other things I should replace/upgrade while I have the engine out?? This will be the only time this truck will get this type of opportunity and attention.

 

Get your crank sensor from the dealer......