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Wow, that's good information right there. I went ahead and worked a deal with a local fabricator to get the Freightliner intercooler shortened for free. Pics to follow in my build thread.

Sorry I haven't updated my build website in quite a while. I don't normally update the website until that portion of the project is completed. I left the transfer case where it is. The transmission output shaft stayed stock. I simply moved the engine/tranny forward in the chassis. It looks...

That's not correct. I used the factory deuce transmission output shaft that connects to the transfer case. I did, however, purchase a companion flange for the AT545 output to mate up with the factory deuce output shaft. I recall the output shaft having a 12" overall length, but 11" if it's...

With my Cummins 5.9 + Allison AT545 swap the only things that are electric are the starter, alternator, and the fan clutch. I converted the shutdown solenoid to use the factory mechanical pull cable.

Pretty much everything you ever wanted to know about the Allison AT545 is at the link below (including measurements). http://www.messb.com.my/allison_at_545.html