Mechanical Differences Between 1500 and 2500?

[Dan Timmer]

I have just purchase a rolled 2003 1500 parts truck so I can put the low mileage 5.7 hemi into my 2003 2500. I understand the major differences (frame, axles, suspension, ride height and quality), but my question is, what are some of the smaller mechanical things you might not think about? (trans coolers, bigger radiator, bigger alternator, steering, sway bars, etc.) My parts truck is much cleaner and lower mileage than my 2500 so I would like to use as much from it as possible without jeopardizing 2500-specific features. So far I have (let me know if I'm off the mark):

-1500 uses NP241/3 t-case; 2500 uses NP271/3
-1500 has ifs and Chrysler 9.25" rear end, 2500 has solid AAM 9.25? front and 10.5 rear (5.7), bigger brakes and 8 lug on the 2500 of course
-1500 has smaller frame than 2500/3500

 

[MikeT]

I believe the 2500 has a higher amperage alternator, install it on the new engine. If your 2500 came with a hemi, I would look closely at keeping the alternator, power steering pump, air conditioner compressor and anything else that looks heavier duty on the original and bolt them to the new engine. I don't know if the pan on the 2500 engine has more capacity than the one on the 1500 - worth looking into. I have a Cummins so I'm just tossing out ideas on what I imagine might be different. See if you can find out anything about engine internals, oil pump, cams etc.

Mike

 

[HemiLonestar]

Propulsion wise in 03 they are virtually identical. Same engine, same programming, same trans. The coolers are physically interchangeable, most likely you have a larger one in your 2500 already, but if not go with the bigger cooler. Only two options for factory alternators, 136a and 160a. Body parts that year are interchangeable as well as interior. Anything frame or suspension related you're out of luck. Completely different. Take the engine out of the wreck, drop it in your 2500, hook it all up and call it a day. How many miles are on your 2500?

 

[Dan Timmer]

Thanks for the input so far guys. I bought the 2500 over a year ago now and it has sat. Haven't had a battery to it to check the mileage but I know it is pretty high. The trans and transfer case had just been rebuilt and only had a few thousand on it until the original motor went, and I have paperwork on it. I bet I will have to rebuild the axles not too far down the road.

 

[HemiLonestar]

Not necessarily, those axles are pretty herky. Worst case I bet will be seals.