The long road to Bonneville, goals are 40mpg useable pickup in the 150 club

[aardvarcus]

I am surprised by the cost of the Allison swap. I have the 5 speed Allison 1000 in my 2001 2500HD behind the 8.1L big block. All the Allison 1000’s are six speeds, the sixth speed just isn’t enabled in the 5 speed versions. I have heard of people enabling them, but I don’t know about cost. If you are replacing the torque converter anyway, a 2006-2007 Chevy/GMC 2500HD Pickup with the 8.1L may be a cheaper source for a 6 speed Allison 1000. They don’t dip the 8.1Ls in gold like they do the Duramax and low mileage units can be found. (Note the Suburban/Avalanche with 8.1s and the pickups with 6.0 do not have the Allison, despite what sellers list them as.)

If gearing is the only thing holding you back from a manual, you can put together a .648 OD NV4500, I have one not that bad of a job. Got about 3500 miles on it behind a 6.5L, no issues.

[gumby79]

Android Vs internet flipping Gremlin strikes again sorry guys just look at it sideways everything in my blasted phone says the right way is up I can turn the picture anyway I want and it still comes in sideways when I upload.

Step 2 on transmission installation gut the interior. Hard to cut the floorboard with the carpet in place can have to rais the floorboards approximately 5 in in the front to clear the 5.5" flywheel housing and a couple in the back.

Why???cut?
Florebord hangs down to mimic the 46RH profile.


46RH on a 4x4 block to center on crank shaft centerline due to deep pan on Allison.
Notice how much flatter the Allison profile is, almost flat from the flywheel howsing to rear output.



The allison 4speed in pic is 1-2" shorter than the 6 at the rebuilder. Drive lin will have to be lengthened.
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Took the core into an Allison certified repair facility to have it Dyno load tested to find out what I had...
Some of the sensors had been removed from the top side allowing water to get in causing the clutch packs to delaminate as they use a water-soluble bonding agent to attach the friction material complete rebuild required.
Standard rebuild 530 TQ limit $2,400
This will only allow the 10 horsepower gain before reaching the limit has the unique characteristic of the first generation Cummins Dodge is a 3 to 1 torque to horsepower ratio vs 2nd gen and on have a 2 to 1 torque to horsepower ratio this is due to internal differences between the ve and the P pump.

After discussing with the builder what the dyno results were and what my intentions are Bonneville we agreed that an upgrade was necessary to ensure a long and happy life in the Allison extra clutches in every year Harden steals in all except for C2(C2 is damaged by hardened lugs on the steals, I thought about asking him to have the Lugz annealed should I would still get the hardened faces without the drum damage). C2 steals will still be replaced with a thinner units to allow room for the additional clutches. Adding a g solenoid which helps prevent damage that was evident inside the transmission by bypassing access line pressure through the cooler at idle. Replacing the broken torque converter housing. Swapping out the tail shaft housing for a tail unit that has the crossmember mount built in allowing me to cut the big ears off of the SAE #2 flywheel housing, as well as internal Park gear has been verified. All new sensors. he assures me that this will handle a 1000 TQ. Sounds like a massive amount but remember 3 : 1 which means I'll have keep it under 333HP. Didn't really want to exceed 350HP as doing so will start severely compromising the Integrity of the engines lifespan. Quote was under4- 5 grand out the door all I need is the computer and harness from Jason in Montana

[redpoint5]

Originally Posted by gumby79

Android Vs internet flipping Gremlin strikes again sorry guys just look at it sideways everything in my blasted phone says the right way is up I can turn the picture anyway I want and it still comes in sideways when I upload.

It's no gremlin; it's perfectly predictable. Forums always display photos in landscape (longest side horizontal). If you take a photo in portrait, the forum will display it in landscape. There's no rotating if you take it in landscape to begin with though.

You can pad your landscape photos with blank space so it's at least 1 pixel wider than tall, or you can crop the photo so it's at least 1 pixel wider than tall.

[aardvarcus]

Grumby79,

I didn't realize you were so far into this swap, not trying to Monday morning quarterback you with my prior suggestions. Looking good, this is quite the project!

[slowmover]

Nothing easy about transmissions. Any type.

[gumby79]

transmission arrived thursday
The trans took a couple extra days. He has a load cell / trans dyno and found a cracked valve body making the trans miss behave then had to source and mod it for the shift kit reinstall and redyno. the trans has the Alto G3™ Friction kit including Kolene® Steels .
5k final price 24 month/ unlimited mile warranty (includes Bonneville use). Included 3 disk Torque converter , GM bell, rear mount tail shaft housing, upgraded internals , and swapping the 3rd gen(5sp pre 06) Allison for a 4th gen(6sp 06+) . after further research I found an individual that had already transplanted an Allison into a a 1st gen cummins he said that and he only had to do minor clearancing to fit the beast. so "I changed horses mid stream" and decided that the extensive mods and body lift required for the SAE#2 bell was not going to help my end goals for Bonneville. This decision had a price of $1495.00 for a cummins to GM bell Allison motor plate with the proper SFI 29.3 flexplate (SFI required by Bonneville regs to pass 150mph). FromCa Conversions, box including $ 2500.00 6 speed wire harness kit with tap shift ( manuel mode) $ 295.00 throttle position sensor kit $ 500.00 2 line indicator PRNDM/123456, should be arriving next week.
If SFI is not required then Summit has a motor plate with non SFI flexplate
for (as of 3/19 ) $995.99.



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aardvarcus
the info although does not help me as I already took the leap it will help the next person that used my build as reference for there Allison conversion. A stock Allison would be fine (and I was going to run the 5sp with 6 sp programing had it tested ok) if the HX35W/12 did not cause my TQ # to exceed ~535 TQ (only 44ft lb buffer fron old turbo) seat of the pants says it would have been risky. dyno run will tell the tell.
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redpoint5 thank you for the tip. what about the ones that load upside down?

[Big Dave]

Gumby:

I'll sell you a nice Ford diesel with a six speed AND the Gear Vendor overdrive plus 3.08 gearing.

See the "For Sale" forum.

[gumby79]

Its in now to finish pluming, wiring, and shifter +tap shift switch




Conecting the 2 lines shown has proven difficult as not even the hydraulic line shops seem to have anything for 1/2 inch inverted flare. Transmission Builders seeing what he has in his resource bin in Dallas Texas

[freebeard]

Details, details.

My SUPERBeetle is running again. It was the machine screw that holds down the Hall Effect sensor in the distributor.

[Piotrsko]

Looks like Aircraft AN8 double flare to me......

Freebeard had a screw loose?