Here is my thread about the swap.
3rd gen Cab Swap/Rebuild - Competition Diesel.Com - Bringing The BEST Together
Notes from the differences in cabs:
Things I've noticed from doing this swap so far, gas to diesel cab shells. There are some holes for battery box mounts that need to be tapped on the passenger side. M8 x 1.25 tap.
The SRS airbag module that mounds on the trans hump under the dash, mounts different from 03-05. It's easy to modify and I used a self tapping screw to make it work. Self explanatory if you see it.
Knocked out the hole for 4wd shifter. Had to move the rear seat back cab wall mounts from my 05 to 03 cab. The 03 trucks have a one piece rear seat and 04-05 have 60/40 rear seat. Very easy.
I noticed the seat belt material is different from 03-05. This would bother me so I swapped over all my 05 seat belts. Headliner also has a different pigtail where it plugs in at the driver side a-pillar by the dash.
Windshield wiper motor has a different plug, so I swapped over my wiper assembly from the 05.
I've been extremely pleased with the Blend Door USA stuff. Only way to properly rebuilt a Ram MVAC box, IMO.Absolutely use mopar core and evaporator. I would also highly recommending addressing the damper doors while access is easy. I found the earlier damper doors (02-03) to be stouter in construction when comparing to my 05 damper doors. So I used the 03 doors from my donor. In the end, I should have bought the aluminum doors.
Pull up that carpet and lay some sound mat under it. Especially the back wall of the cab.
Good luck with the project.
Two things I found different on the donor cab, which I find weird with it being older than my cab. It has these plastic covers and plastic inserts at the lower rad support.
Tomorrow I’m lifting the bed and cab off, so we’ll see how that goes.
I do know that my diesel cab is Mexico and the donor is a US cab, maybe that something to do with it.Interesting... I currently have the front of an early (47RE/235HP early!) 03 2500 apart, and it doesn't have those plastic things. Must be an 02 1500 thing...
After the issues we've been fighting with parts made in Mexico here at work lately, that wouldn't surprise me. Some quality shit coming out of that country right now.I do know that my diesel cab is Mexico and the donor is a US cab, maybe that something to do with it.