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Thanks for the part numbers. What is different about the AMG o-ring? Any visible differences in the two adapters?

Strongly recommend ditching the sock. Yes it provides more surface area so if a leaf or other similar debris got into the tank it could still pull fuel. But not worth the hassle in my opinion. Dropping the tank or pulling the bed is a PITA, toss it when you pull the new sender out of its box...

The crossover is all tacked up. I really recommend doing this with the engine in the truck. Doing so on a stand it would be really hard to account for all the frame clearances. The mock up engine is in a 1993 K3500 Cheyenne 1 ton dump with a blown engine. The new heart for the vehicle is...

On the other side, I really wanted to use another Vband connection. The Banks manifold comes with a 2" 3 bolt flange cast into it, so I welded a 2" vband directly to a stainless 3 bolt flange. Getting away from the factory 3 bolt flanges was a goal here as well However, when trying to add in...

The goal of this upgrade is better exhaust flow, so stepping up to 2" as quickly as possible is the goal. On a whim I had purchased a 45* piece of 1-3/4" pipe, and I'm glad I did as it allowed for a smooth transition around the front diff mount and good orientation towards the passenger side...

A few more pictures showing the tight clearances On a 4x4 truck clearing the front diff mount has to be accounted for too

Additionally, even though the manifold is 1 3/4" in diameter on the inside, the flange accepts a 2" vband clamp. So without milling it smaller a 1 3/4" vband wont work. This proved helpful though, as to gain all the clearance I needed I slipped the 1 3/4" elbow into a 2" vband and made something...

I didn't get any pictures of the milled face, but will add later. Next up was to figure out the power steering. On the 92/95 trucks, the pressure hose from the pump to hydroboost sticks out pretty far behind the pump and points directly at the van manifold There are several workarounds to...

After sitting on my shelf for 2 years, I finally got around to making this upgrade happen. Sadly the Sidewinder manifold is discontinued and no longer available from Banks, but hopefully this helps the few who already have one or are lucky enough to score a used one. There are several others...

Welcome to the forum! Nice looking rig. I really dig the 2 door diesels, not many of them were made. And nearly impossible to find any up here not rusted to pieces. Is this your first 6.5? They can be a reliable engine if taken care of right. They're pretty particular about certain parts and...

Glad to hear you've narrowed the problem down some. Not sure if you're in the salt belt or not, but I personally can't stand the saginaw flare & o- ring fittings on the tank pickup/ sender unit. They seize up in salt country and usually leads to replacing sender and lines. If you're feeling...

This is the intercooler I purchased https://www.ebay.com/itm/314019994048 Core size is 23" wide by 11.75" tall and 3" thick. Overall width according to the pictures between inlet and outlet is 30.75" it is definitely the largest cooler that will fit between the frame rails

Yes, #11 is correct for what I'm referencing. Same fastener is used on a manual transmission truck on one of the top passenger side bellhousing studs for securing the clutch line. The double ended stud also had a grounding strap on it from the starter on my '95

Found this, good to know it's still out there for securing starter heat shield to bellhousing https://paceperformance.com/i-19863171-11546890-stud.html

@SnowDrift heads up too that the bolt holes for securing the transmission to the engine are metric, M10x 1.5 on the GEP block. The early 6.5 blocks like yours most likely have 3/8- 16 threads, my '95 141 block did. I just thought of this as I'm putting a GEP block in a '93 and the bellhousing...

I'd also highly recommend installing while the engine is out

@SnowDrift the motor mount to block threads are M10x1.5 as I thought. The starter brace to block was a bit more tricky. M8 x 1.25 seemed the closest but I didn't want to chase it too much on the block. My tap kit doesn't go any more coarse than 1.25. In searching around it seems the correct size...

Sorry I didn't get to it tonight, 12 hour day putting up a deck and just got home. Eat bed turn around do it all over again. I'll try to report back tomorrow What is visibly larger, the motor mount to block bolts?

Most everything on the engine is a M10x 1.5. The motor mounts from my '95 fit my P400 just fine but I can check the thread sizes on the block for ya tomorrow after work x2 on the starter support bracket being M8x 1.5 but I can check that tomorrow too I'd also recommend new starter bolts, don't...

Question- apologies if it's already been covered here- Will the GMT400 wheel hub/ bearing assembly bolt into the GMT800 knuckle? And will the 800 series rotor slide over the hub without issue? I'm doing this conversion first to a '93 which didn't have ABS sensors. I know the 800 rotors slide...