1996 Dodge 2500 12 Valve Cummins to 24 Valve Cummins Conversion

[6lcummins]

I finally got all the parts rounded up and started doing this conversion a few weeks ago, as I had time. I had traded a 12V for a running 2000 HO 24V that had a 3-day-old VP44 on it when it was wrecked. It turns out the engine is a 53 block and instead of rebuilding one of my spare 12V lower ends we are going to see just how long the 200,000+ mile 53 block lasts. I planned on a mild build originally but with parts lying around it has turned into a pretty aggressive street build. Currently it has a stock cam and valve train along with stock push rods. It now has a 180 P7100 in place of the HO VP44, it has full cut DV’s, 0 plate and a Columbus Diesel 5K GSK. It feeds 7*0.014” SAC injectors that I built and set to 285 bar. The truck already has a South Bend 3400 Dual Disc and for the time being will be running a Schwitzer S366SX3 turbo until I can figure out which compound setup I want to run.

Tearing the engine down on the ground as the engine stand is full of a 12V







Swapping the 24V(right) cam gear with the 12V(left) cam gear









P7100 Front Gear Housing/VP44 Front Gear Housing/New P7100 Front Gear Housing


Timing Pin Housing: Notice the “Star” washer that holds the timing pin in place. Discarded due to the fact its not needed and is a PITA to get out with P7100 and vacuum pump/power steering pump installed.


Transferring mounting studs and timing pin housing to new P7100 Gear Housing


Cleaning and Installing New P7100 Gear Housing



Installing Cam



Replacing Rear Main Seal






Aligning timing marks and reinstalling oil pump




Oil pickup tube and oil pan installation




Tappet Cover Installation



P7100 Mock Up



Over Flow Valve clears without issue


Factory 12V oil feed location


Moved the oil fitting to the driver side of the P7100 for easier installation of the oil line and used an extra port on the block just behind the P7100 for dedicated oil feed for P7100


Vacuum Pump/PS Pump and oil feed lines mock up





Intake Plenum and Lift Pump masked off for paint




P7100 24V Conversion Lines mocked up




Installed primary turbo drain and A/C water inlet installed




ARP Studs Installed
















Installing stock pushrods and valve train









Painted block VHT Gloss Black Industrial 24V Valve Cover and Lift Pump Delete








New Water Pump, Front Seal/wear Sleeve, and KDP Fixed









Rear and Side Billet Freeze Plugs







Rear Adapter and Clutch Install





Coolant Bypass




P7100 Modification



Injector Install



Final Assembly








































Started for the first time and found timing to be off


I retimed it but don't have a good video of it right now but will post one when I get a new one.

[propanemudtruck]

Awesome buildup post! What was the time frame start to finish in the pictures?

[6lcummins]

I started on it the last Sunday of October and worked on it for a couple of hours a day in the morning before work and most days on the weekend when I wasn't working on a customers truck.

[Dieselwrencher]

Aren't you glad to have it running again? Nice job Nick. Now don't blow it up!

[6lcummins]

Got a lil time today to play with it and did a little "break in" burnout.



Looks like the limited slip needs rebuilt...

[68panelman]

Nice build!! I have a 2001 3500. Curious what year did that valve cover come from? I really like it.

[6lcummins]

Thanks, been a long time coming and a lot of time too. I'm glad it only netted me a few little issues after running her hard.

It's actually an industrial valve cover.

[Dieselwrencher]

Other than the throttle being super touchy, it ran good for it's first time out!

[6lcummins]

Yea, touchy is not even close, I guess ill have to put a couple springs on the return and make it stiffer. we shall see.

[6lcummins]

[spudz]

awesome! I have no idea what all the diesel talk is about but looks like good work! lol. Hey is that a old Hemi I spy on the shop floor?

[6lcummins]

Thanks, and yes, that is a 354 Hemi for my brothers 40 Ford...

[6lcummins]

My brother and I took our trucks down to one of our suppliers that has a dyno in house and did a little bit of tuning. She doesn't run too bad for being in street trim.

[mosesburb]

Sounds bishin'.

I think it might be running a little rich though......

[tecky11]

subed, great progress

[6lcummins]

Thanks, it's a whole different sound in person though. by the way, remember the Ford we had issues with a couple weeks ago on our trek west? Here she is all fixed up, you wanna see rich...

[Car'n'Guitars]

Be careful man I've many bad things about the 24v Cummins, and I believe are either in or had a class-action lawsuit against them for cracked blocks and heads. Good looking truck though, and good luck.

[6lcummins]

Originally Posted by Car'n'Guitars

Be careful man I've many bad things about the 24v Cummins, and I believe are either in or had a class-action lawsuit against them for cracked blocks and heads. Good looking truck though, and good luck.

They aren't as bad as you have been told, it was only one casting that had issues and they are rare. The class action lawsuit was on the "53" block and people got $500 if they were the original owner of one.

As most know, I got this engine for free technically, I have a choice of a couple spare blocks if this 200,000 mile plus engine decides to crack. I left it internally stock for this reason and did this as a joke:



Notice the red painted 53, makes it obvious to those that dont knwo where to find it. I did it on both sides

I also installed this to help prevent the cause of the block cracking:



If it cracks so be it, then a real build can be done to make better numbers and go fast.

[Car'n'Guitars]

Cool man, we have a 97 12v Cummins and I love it still both are great trucks. Hope it holds up for you.

[6lcummins]

If it doesn't its not a big deal, I know what I got myself into and as long as it hold until I get my long block done I'll be happy. Especially since this thing, with a stock cam, has an envious power band:



This is the Street setup too, but I'm extremely happy that it may drop 20HP over 600RPM range, which the middle of should be where it carries down the track.

[Car'n'Guitars]

As long as it's fun right I guess that's all that matters.

[6lcummins]

Exactly, I know this engine won't be a dyno killer or a 2.6 winner but for a street truck with very little money in it this engine will do the job just fine. The new engine build, well that will be hard to handle on the street.

[BLAZERMAN]

Cool build..and she sounds Great!! Whats the idea behind the bolt-in freeze plugs? did these motors have a problem holding the stock plugs?

[6lcummins]

Originally Posted by BLAZERMAN

Cool build..and she sounds Great!! Whats the idea behind the bolt-in freeze plugs? did these motors have a problem holding the stock plugs?

The bolt in are for reassurance, the only plug that has a known issue is the rear. Since my engine has the capabilities of 5000rpm plus, it's added safety to not hurt the engine, plus they are reasonable to get. My goal was to do everything I could to make sure this engine lasts.

[Dieselwrencher]

Originally Posted by BLAZERMAN

Cool build..and she sounds Great!! Whats the idea behind the bolt-in freeze plugs? did these motors have a problem holding the stock plugs?

The freeze plugs like to blow out above 4,000 rpms due to the volume of coolant being moved in the system at the higher rpm ranges.