2005 Dodge Commonrail to 12v swap

[DerelictDodge]

New to posting but I've lurked around here for a couple of years. Seen a few awesome builds now I've got a chance to do one myself. Bought my first diesel about 4 years ago (1999 Dodge. 24v 5spd 2wd dually) and been hooked ever since.

Found this truck on Craigslist. It's a 2005.5 Dodge ram 3500 2wd. Interior is perfect. Body has a few blemishes but nothing major. Has over 300,xxx. Tires look like new. Has airbags in the rear. Owner ran the truck out of oil and destroyed the commonrail that was in it.

Why I'm going this route. I want a truck that's a crew cab, rides nice and is essentially "bullet proof". I couldn't salvage the original motor and I've heard horror stories of common rails melting pistons, so I couldn't justify buying a used engine and possibly running into that problem myself.

The donor motor is out of a '96 one ton dodge with an auto. It has the 160hp p-pump. Motor only had 160,xxx miles on it. The truck was wrecked but I was still able to see it run. Hauled it home and I've been collecting parts for the build for about 3 months now. Slow progress but I'm in no hurry.

[DerelictDodge]

Scored a used DPS 3pc manifold. Hoping to run a single aftermarket turbo. I've been looking at an AFE street series BladeRunner turbo. I don't plan on messing with the p-pump much if any. Could use some advice on the brand if anyone has an AFE.

[Red Sleeper]

Going to be a cool project. Interested to see the end result and hurtles yet to arise.

What transmission are you running?

[DerelictDodge]

Thank you Red Sleeper. I'm running a nv5600 in this truck. It came with a g56 but i'm unsure of it's condition. The only major problem I see ahead is the wiring. I'm sure that it will be fun.

[j.fondler]

I put a 12v in an 03 gasser. The wiring was the biggest pita of the whole project. Not sure what a commonrail has for cam/crank sensors, but I had to rewire much of the truck to get everything to function properly without all the sensors from the gasser. ECM is dead without them.

Good luck, looking forward to seeing the swap

[DerelictDodge]

Thank you j.fondler. I'm sure the wiring will be a chore. Just glad to have a daily driver so I don't have/need to rush with this truck.

For an end result I'm looking for a good hauler/driver. I chose the nv5600 over a mid sized transmission like an Eaton Fuller. Looked into an Eaton swap for a while but most builds required heavy floorboard modification. It took me FOREVER to find a used 2wd nv5600 transmission. Had to result from buying one off of Ebay. Hopefully it's not a pile of junk. Should be showing up by the middle of next week.

I would love to hear how you did the fuel system. Making the fuel gauge work, what pump you used ect.

[pushlar84]

I've done a common rail to 12 valve swap

[pushlar84]

Left the ecm in it, hooked up crank sensor similar to the common rail. Then just adapted the rest of the sensors. Only thing I didn't care for was placement of drivers side motor mount. Dropped it pretty close to pan and wasn't level, little welding took care of it

[DerelictDodge]

Thanks pushlar84. I've heard the motor mounts are tricky. I plan on fabbing up my own. I may need to catch up with a few of you that have done this before a little further down the road. Thinking about making a bracket to hold the ECM. Maybe attach it to the inner drivers side fender.

[Ghostman]

Interesting. As said I think wiring will be the biggest hurtle.

[DerelictDodge]

Thanks Ghostman. I'm sure the wiring will cause me to pull my hair out when I get to it.

Got the engine lifted and put on the stand. Pulled the head off of it and it looks great inside. The cylinders still have good cross-hatching. Going to replace the gaskets and put head studs in. Should have some goodies showing up this weekend. With all the ordering I think the fed-ex guy is gunna know me by name by the time this project is over.

[DerelictDodge]

Little project this morning. Used the bottoming tap to clean the threads up. No major progress but slow and steady. Then went out to cut a load of firewood.

Going to get the 60lb valve springs in tomorrow hopefully.

[thunder03]

Wiring can suck. But just take your time and double check your connections and you'll be fine.

Looks like it'll be a nice rig when you're done.

[DerelictDodge]

Thank you thunder03. Yeah wiring sucks. I'm sure it will be the most time consuming part of the build.

[RandomHero]

I have never done or attempted the swap you are, but I know that what has helped me with big wiring jobs in the past is making two lists. One for the chassis and one for the donor engine. It was easier for me to cross reference that way, granted I was only converting an 03 into an 06, still made life much easier.

[DerelictDodge]

Thanks RandomHero, thats something I'll keep in mind. Good idea. Luckily I took the truck apart so none of the wiring was cut. Couldn't imagine trying this with hacked wiring to begin with.

[DerelictDodge]

Little update today. Got my PacBrake 60lb valve springs in. Put new valve seals in while I was in there. This tool they sell came in handy. Not a hard job to do, only took about 45 mins in all.

Also got the block surface and head surface cleaned. Put the new head gasket on and set the head back on. Head studs are finger tight in the block. I won't be able to torque the head down until I get the rocker pedestals milled down. I don't want to try and just get by with grinding the webbing out of the valve covers. Spend a little money and extra time here so later on down the road I hopefully won't run into any oil leaks or other problems.

[95cummins5.9]

I would have the head surfaced while you are having the rocker stands machined. Cool swap bud.

[DerelictDodge]

Thanks 95cummins5.9. I thought about having it surfaced but i'm hoping it will be fine as-is. Hopefully it won't come back to bite me in the end.

[Red Sleeper]

I am jealous of your JD mowers. The hoods are in one piece on both of them!

X2 on getting the head surfaced while it is off. I reference your earlier post about spending a little extra money and time to prevent a problem down the road.