I have a 1994 Thomas Built school bus with a 160hp ppumped engine and Allison 545 transmission. I'm wanting to swap this engine into my recently purchased D250. I've been trolling the forums and find alot of different info about this engine. Just curious if anyone on here has any more input about this. I've read the oil pan will be to deep and will not work. Will the pan from my 91 engine fit and just swap over. I've read and can see that the exhaust manifold sits lower and will not work. Will the manifold from my 91 swap right over. Also the bus has air breaks and an engine mounted compressor. Will this cause any issues pertaining to fitment, can i just remove it. Not sure if it's gear driven or belt driven so unsure what modification will be required. Just throwing it out there for any advice. Thank yall in advance.

 

Also I'm planning on using the Getrag from my 91 behind the 94 bus engine. Will the engine adapter plate mount up no problem. I'm assuming it will because I've swapped my stock plate to a 2nd gen plate for the 47rh swap and nv4500 swap so I'm sure the 1st gen plate will fit the 2nd gen engine. Any knowledge yall could throw my way would be greatly appreciated.

 

I believe the fan and fan mount system will have to be swapped and thermostat neck

 

Will the components from the 91 engine swap right over?

 

Yes the '91 stuff will bolt up.
Whatever is different, exhaust manifold, turbo, motor mounts, A/C pump, intake horn, intake plate, oil pan, fan and fan hub come to mind.
All those parts will just bolt on off a 1st gen motor.
The throttle linkage and cable might take a little custom work to use on a P-pumped motor.

 

Good deal, that's what i needed to hear. Thank you Mr. Foster. Can't wait to get this project started

 

Like oliver said, everything will bolt up externally. You will also need your old bellhousing adapter, 545 runs an SAE bellhousing. Have fun!

 

I still have the bellhousing attached to the Getrag so that works out perfectly. Thank yall for the input. Hopefully i won't run into any big snags along the way

 

assuming that it has the downward facing "industrial" exhaust manifold? most guys will give their left you know what for that manifold when doing conversions and such. can't see why it wouldn't work for you if it is indeed the one i've seen.

 

Not sure if I've got that type of manifold or not. Why would it be more desirable.

 

 

That is a different looking valve cover extension tube for filling it with oil and the dipstick looks like it is 5 ft long!
Just a question of finding and swapping over the correct Dodge parts now.

 

Keep that little Cummins emblem for a dash plaque. they are smaller than the ones on the bigger engines and not as easy to find.

The manifold is desirable for clearance in some engine swaps where there ia more room at the rear of the engine compartment.

 

Yeah that's the sad part, i have every part i need to swap it over bit i sure do hate to dismantle a perfectly good motor just for some parts. I've sourced several that i need from local buddies and members on this forum. Hopefully the money man will loosen up a little bit and i can run free for a while

 

Well i decided to keep the bus intact for now and swap no non ic motor from my other donor truck into the new to me D250. In planning on resealing the engine/injector pump/getrag before installation. What do yall think about this engine gasket kit
http://cppdiesel.com/mahle-engine-gasket-set-12v-upper-and-lower/?gclid=CjwKEAiAluG1BRDrvsqCtYWk81gSJACZ2BCe3C-szbKrS32_oEcHtEstLuHCHWnk-7Ew8RDAZLmF7RoCf1Xw_wcB