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I still think you're way overbuilding the setup for the use case but, moving past that - you might want to start looking at racing transmissions. This company does transmissions for those cars with over 1000-ftlb input, and they have 6-speeds and a 0.73-0.76 overdrive (4 ratios to choose from)...

Something to note about Eaton part numbers (Fuller, Spicer, RoadRanger - all are Eaton sub-brands): The first number of the second half is the input torque value. So for: RTO-610 The "R" is RoadRanger, the "T" indicates Twin Counter shafts, and the "O" indicates Overdrive. The "6" is the...

Take a look at the FRO-11210C, 10 forward speeds, 2 reverse, 1150-ftlbs of input torque, over drive of 0.74:1. The only obvious drawback I can see is that the transmission appears to be a twin counter shaft setup. It will also weigh twice what the transmission you take out weighs.

This guy put a 13-speed in a 3500HD - note that the later 90's model trucks moved the fuel tanks inside the frame, so the frame is actually wider under the cab where the drive-train goes. It may be harder to cram a double counter-shaft transmission in the square-body style truck, at least...

I selected a Fuller FSO8406A for my build-up - 6-speed, overdrive, tons of input torque, lots of PTO options (3 ports, one each side, and one below output shaft on counter-shaft). Any transmission you pick from medium duty trucks should fit with minor firewall surgery, transmissions from heavy...

so they say, but look at the vapor perms - if it's over "1" (i.e. not a decimal or fraction), it's only a vapor retarder. Yes the newer Allison Transmissions are TCM controlled, but there are kits available to run them with a mechanical engine. I Google search for Cummins Allison 2000 produces...

If you want to allow your wife to be able to drive it - teach her to drive stick!! (J/K). You might look at the Allison 1000 and 2000 series automatic transmissions. They use these behind Duramax GM diesels now, and if you get a 2006+ version you can have a >750-ftlb input torque rating. It...

If you're going to have the injectors and pump reworked, why not also do the engine? If you're keeping the 4.56:1 final drive, and 37" tires, you're going to have difficulty putting that truck on a freeway unless you get an over drive transmission - a 1:1 (direct) top gear will get you ~68MPH...

I doubt that cruising is going to require or produce 800-lbft - you might get that if you are rock crawling in low range with a tire wedged between two immovable rocks, right before your drive shaft collapses, maybe closer with towing... Remember that there is a governor that fuels the...

Yeah, the question is how dressed, cast headers can add 60 lbs... plumbing and filters (also wet) another 30 lbs. That pushes it over 800 from your friend's number - not really sure how dressed he saw them and with what options. I feel you on the weight with age thing...

Engine hoist and a calibrated scale. This is an AC compressor, power steering pump, headers, Alternator, oil, etc... The 500-600 lb numbers I've always seen is dry and unassembled, not wet - and certainly not dressed.

A fully dressed 6.2 comes in over 1000lbs - apples to apples you're probably looking at a 300-500lb difference, that said, don't expect to use 30 year old leaf springs to support this. A DT466 weighs a little more than a Cummins 6BT 5.9L. Stuff like this has been done, but probably not...

Realize that a diesel does not have a wide power band - it's usually 1000RPM-2300RPM, only about 1300RPM wide (a "gasser" can have a power band of 1000RPM-4500RPM, almost 3x the size). A 4-speed is probably out, you might get away with a 5-speed, but a 6-speed will give you better drivability...

How much toque do you want? Gears/boxes are rated in torque. The DT466 has a separate flywheel housing - you can get it in SAE #3 (smallest) through SAE #1. Pretty much any torque converter, clutch, and transmission is adaptable to that engine. The transfercase issue can be solved by going...