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Replace my '96 6.5l engine with a gasser?

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5akman

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Ok, don't execute me, this is a legit question.... I believe. I have a work truck (1996 CCLB 4wd) in AK that I only use about 5 weeks a year and then it sits. It's got about 160K on it and its giving me trouble. I've checked and replaced grounds/PMD/lift pump etc (this is my third 6.5L, so I've been around the block a few times with common issues) and its just flat out unreliable and based on the short time that I'm in AK, I need something a bit more turn key! I've got a low mile SBC 350 sitting on the engine stand that I built for a boat a few years back and then pulled it out when I sold the boat. I'm wondering what is involved with such items as engine mounts/electrical/bellhousing etc. If add an aftermarket TBI type unit to the 350 and then installing it is somewhat straight forward, then I'd give it a go. Otherwise I'll put it up for sale next summer before fishing season. Has anyone done this before?
 
I'd be more inclined to sell it and buy something else vice swappingin a gas engine.

Biggest issue is the 4l80e. It's computer controlled. One of the things it needs is the app signal. A tbi would be cable actuated and have tps. I don't think that would work with the current PCM at all.

You could go 700r4, but that also brings with it lots of hassles.

Maybe find a tcm from a 93 for the 4l80e, but with that comes wiring issues.

You could sidstep all the electonics on the engine problems with a carb, but you're right back into transmission territory again.

Swapping in a db2 might be an option if the electronics are what's giving you fits. I think Bobbie Martin works out a way to use the electronics with the mechanical pump, but don't quote me on that.

If I were to go the gasser route, I'd buy a wrecked small block truck for the bits and pieces I needed (ie: mounts, cables, etc) and just swap 'em over. Then drop your new 350 in the middle of it all.

I'm not saying you can't swap a 350 into it, it just sounds like a pretty big pita to me. That's a lot of work, money, time and hassle for a "5 week a year" truck.

Yup, selling sounds like a mighty attractive option to me....
 
What about a Cummins swap.....They are supposed to be pretty doable....Ask Leroy (aka Burning oil-PMDCable.com), I think he's done 1 or 2.

You'd have the Ultimate hybrid.....A Powerhouse Powerplant in a lovely wrapper!

JMO-2 Cents
 
I bought a 2 blown 6.5s from a guy that switched to a 454. He had the whole donor truck to get the wiring harness out of. It was the same year donor truck. You will need the fuel pump and fuel lines from a donor also.
I'd have to agree with GW . Do able, but not worth it in my opinion.
 
What kind of trouble is it giving you? Must be bad to think about a gas engine with fuel prices up there.
 
Even with a Cummins swap you still have the trans controller issues. You can get aftermarket controllers. Not sure where prices start, I think $600. The Compushift starts at $1000 its the one I would use next time.
 
GM performance parts does offer a 4L80e controller for no ecm installs.

But you might be money ahead to move on to a different vehicle, unless you have the location and time to do the swap.
 
There is a cheaper alternative to the Compushift although I have no personal experience. Can't remember the name but wanna say it was Optishift. Was around 600$. You have to watch emissions laws in your state. it is a violation of federal and some state laws to change a vehicle fuel type or tamper with any emissions devices. That said you may not be able to get an emissions test done on it if your state requires it as the trucks vin will come up diesel. I know you'd never get a sticker on it in CT.
 
I am pretty sure obd1 TBI trucks have 4l80's in 2500 and 3500 trucks (in 94 and 95's for sure) and you could convert your 96 to a 95 obd1 but when/if it gets emission tested it will need obd2 (96+) data.
 
I dont know about AK, but in NY (USA), it is illegal to go from OBD-2 back to OBD-1. YOu can go vise-versa though. Way more of a hassle, just sell and get something else if thats the only solution besides fixing.
 
Yes, with my limited time up there each summer, selling and getting a different rig makes more sense.
 
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