Shoehorning a Cummins engine into a Chevy Avalanche isn't easy. Getting it to run isn't, either. Nonetheless, Jeremy Mathews of New Paris, Indiana, was up to the task. Over the course of five months, he spent afternoons and evenings pursuing his goal, and in the end he accomplished what he set out to do. The result is an ultra-unique rig that even makes us drool.
 Other than a tall lift and...  Other than a tall lift and some 39.5-inch Boggers, Mathews' Avalanche looks relatively low-key. The surprises start when you open the hood and look underneath. |  Up front, there's a Stealth...  Up front, there's a Stealth Off Road front bumper. Mathews added a custom brushguard. Speaking of bumpers, he designed and created a custom rear bumper as well. |  Out back, Mathews retained...  Out back, Mathews retained the Avalanche 2500's 14-bolt axle, but he swapped in a set of Atlas 12-inch-lift springs and a set of Rancho shocks. |
 Yep, that's a second-generation...  Yep, that's a second-generation 5.9L 12-valve Cummins diesel engine that has been rebuilt and fitted with 80hp injectors. Getting it to fit and run properly required a slew of creative solutions including a body lift, a custom radiator, a custom intercooler, and tubes, plus replacement of almost every frame crossmember. |  The stock GM instrument cluster...  The stock GM instrument cluster wouldn't have been the least bit happy with the new engine and transmission, so Mathews created a custom cluster using Stewart Warner gauges. In addition, he can monitor critical areas via gauges mounted in an A-pillar mount. |  The stock IFS was kicked to...  The stock IFS was kicked to the curb, replaced by an Off Road Unlimited straight-axle conversion kit. This leaf-spring setup with dual shocks at each wheel locates a beefy Dana 60. |
Backing up the Cummins engine...
Backing up the Cummins engine is an Allison 643 transmission that was sourced from a Ford dump truck. The trans rests on a custom mount and feeds a divorce-mounted NP205 transfer case.
GENERAL
Owner: Jeremy Mathews/New Paris, Indiana
Vehicle/Model: '02 Chevy Avalanche 2500
Estimated Value: $50,000
ENGINE
Type: Cummins 5.9L 12-valve turbodiesel
Aspiration: Turbocharger, intercooler, 4-inch-diameter exhaust
Output, hp/torque (estimated): 500/1,000
DRIVETRAIN
Transmission: Allison 643
Transfer case: Divorced NP205
SUSPENSION
Front: ORU 8-inch-lift leaf springs, dual Rancho shocks
Rear: Custom Atlas 12-inch-lift springs, Rancho shocks
AXLES/DIFFERENTIALS
Front: Dana 60/Open
Rear: GM 14-bolt/Limited-slip
Ring-and-pinion: 4.10:1
WHEELS/TIRES
Wheels: 16.5x14 Weld Outback
Tires: 39.5x18.0-16.5 Bogger