Re: Let's Build A 1 Ton Crew Cab 4x4
 

Yeah that seems to be quite a few people's opinion. That is should fit I just need to move the rubber mount inside the clamshell some.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

the 6.2 will bolt up but the pipe fitting is smaller than the 6.5. my 6.5 has donuts and the 6.2 didn't or maybe it was the other way around.
how many miles on the 6.5? might just be an issue with the PMD.
love the GMT400 HD's. esp crewcabs.
you're inspiring me to jump on mine and get it back on the road.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Feels good to inspire someone and give them a little motivation for their own project.

Are you talking about the exhaust manifolds?

I think the engine had less than 200K but it wasn't low mileage or anything. We tried to get it to fire up, it turned over great! I unplugged the glow plugs and pulled the fuse and shot some starter fluid in and it acted like it wanted to fire up but after enough cranking over the starter made a little grinding noise so we stopped and I just went ahead and pulled it.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I pulled the engine back off the frame to do some checking and what not.

http://i1223.photobucket.com/albums/...ps42goco6b.jpg

I also removed most of the TBI harness that will be coming off at some point.

http://i1223.photobucket.com/albums/...psiv5bmqwp.jpg

I need to clean and paint the firewall black. What is the best thing to use on the firewall that grease/oil wont stick to? I thought about under coating it or a type of rhino liner, something that will also maybe deter a little heat? I just don't want to spray paint it but I am not set up to do a legit paint job yet either.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I would not use starting fluid on a diesel. lots of warning about it but I'm guilty also. I use WD40 instead now.
make sure you install the rear brace on the starter when you get it replaced. broken cast iron mount ruined the engine that was in the truck when I bought it. reason it only cost 700.00.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I thought WD40 has changed and isn't flammable and wont work anymore, that is why I tried starting fluid. Overall I only used maybe 2- 1 sec squirts. The discouragement is when people spray the heck out of it or leave glow plugs wired up. I think. Still learning.

I saw someone who was successful in using the 6.5 ds manifold so may still try it, it wouldn't fit b/c it still had a cut piece of the down pipe attached to it.

Starter brace? I will look into it. Starter looks perfectly fine though, the flywheel was a tad chewed up but starter still looks fine. Engine still turns over nicely as well.

Only discouragement I have is that I can't seem to find anyone who has kept the electrical pump in the swap or all of the wiring. Most just convert to the early 90's 6.5 mechanical pump, which isn't something I particularly want to do.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I will not use wd40 in a cummins. They tend to want to run away on it. Ether with upper end lube helps. But I agree, usually the disclaimer is for the people that want to drown them with it and things go boom. The biggest issue is people don't think of the grid heaters and glow plugs will ignite the ether and that can be seriously not good. Nice score on the 6.5 too!

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Thanks! I think it was a good deal as well!

I used the starting fluid with the upper cylinder lube. For some reason I thought back in the day you could get some that wasn't 100% ether and was a little less harmful.

Oh well, I have high hopes for the engine. PMD is in stock location so I'm hoping it just went out. I also took manifolds off and looked down inside and it looked good. I plan to do a compression test at some point.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Started tinkering with the engine last night. I am trying to learn as much as I can about these diesels. First I wanted to make sure I didn't miss a remote mounted PMD.

I didn't, it was right where the factory put it, and was covered up by a rats nest! I don't know fellas but I think that may have been the problem!

http://i1223.photobucket.com/albums/...psjd9vkrln.jpg

Pulled the filter to check it..

http://i1223.photobucket.com/albums/...pskeksexsv.jpg

Next I pulled the intake cover.

http://i1223.photobucket.com/albums/...psurcnkhes.jpg

I also pulled the thermostat housing, I guess that is what you would call it and I looked down in the heads and down in the water pump and even in the opening where a "350 timing chain normally is." It looks ridiculously clean inside. The turbo was even really tight with no side to side or forward to back play.

I may get it where I can pull valve covers and drop oil pan and if everything looks good, slap it back together and see about getting it to run.

I will need to replace glow plugs, I wish I had an easy way of getting the injectors checked. Fingers crossed I won't have to throw money at this thing!

Also considering PMD relocate of course, as well as the newer style dual thermostat housing and any other little tricks I can throw at it that won't break the bank.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Was there a year the 6.5 came with a mechanical injection pump? We have had lots of those for work trucks and you need to keep a pocket of those PMD's handy. Even remote mounted we had lots of problems.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Yeah 92&93 came with mechanical as far as I know.

Apparently just remote mounting the pmd isn't enough it also needs a heat extractor or "cooler." Also helps to put it where the air will be blowing on it.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

here's a link to the brace. it's an important piece, if it's been removed, something will break:
https://www.google.com/search?q=1996...Es83QNLduRM%3A
my 92 is mechanical. a little power loss didn't matter compared to simplicity.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I'll make sure it is there. I wish I had the 93/94 parts available to play with. It was crazy hard finding what I did find.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I am kind of shocked how clean this thing is coming apart for me to check it out.

These gaskets look nearly brand new.

http://i1223.photobucket.com/albums/...ps6zb4t5ym.jpg

I vacuumed out some leaves and left overs of a rats nest that was around the pmd.


http://i1223.photobucket.com/albums/...psijhxwrk0.jpg

Pulled the valve cover off as well... Still looking good in my opinion.

http://i1223.photobucket.com/albums/...psyatxih2i.jpg

I finally had some free time to go to my local junkyard where he has a lot of squares but normally charges out the roof prices.

He has a crap ton of transfer cases, I went digging. I think I may have even struck a deal with him to trade a 32 spline tcase for one I had spare from ls swap from a 2001 Silverado. However, I want to make sure I get the right t case, apart from looking at the tag and the normal identifiers I am not sure how to be 100% sure they are for a square. I found several 32 spline 208's and 32 spline 241. Of course I would prefer the 241 b/c of electronic speedo but how do I know 100% sure that it is passenger side drop and will work? Also I noticed a lot of the "hubs" that the drive shaft would bolt to vary, I saw some with a spot for u bolts, some with a 4 bolt circle pattern and some that looked like could be 6 bolt pattern. I go back on Friday to make a deal.

http://i1223.photobucket.com/albums/...pszlg3gpsf.jpg

I also found me some pedals that I have to go back and pull. Hydroboost and Hydraulic clutch. :)

http://i1223.photobucket.com/albums/...ps6r6qmubg.jpg

http://i1223.photobucket.com/albums/...ps63bkjhja.jpg

Another thing I need to figure out is drive shafts. Front and rear. I had the Th400 where it used the u bolts to bolt to the rear of trans, now I will have a slip yolk as far as rear driveshaft is concerned. I will need to modify and shorten it anyways. I would love to get rid of the 2 piece, I swear I saw someone was able to use some ford driveshaft or something at one point.

As far as front driveshaft, how many different types are there? Are they specific for the Dana 60 or will one for Dana 44 work? This is one I have that looks like it would bolt to the 208 or 241 tcase, I swear they used to extend a bit longer than in the pic though.

http://i1223.photobucket.com/albums/...psj13ehn0z.jpg

Oh yeah, bad news $ wise... I got a call from machine shop the day I was supposed to pick up my LS1 telling me it will need to be bored.. There goes an extra $600 probably. I did pull the trans am out the shop and clean it though in preparation to be hauled to my buddies.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Even more bad news $ wise. Machine shop cant find pistons that are 3.903 or 3.905 that are hypereutectic, only 3.908 which is max overbore for the LS1. I don't want to go max overbore when it only needs .005, so far my only choice is to buy forged pistons or go .010 over :( I haven't decided yet.

On another note, the owner of this truck is going on a cruise this Friday and wanted some gambling money. He told me if I could give him some cash by Thursday that he would knock $150 off what I owed him so now the truck is paid off and I have the title :). So that was nice.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Bummer about not being able to find the HE pistons. Probe makes some 3.902 forged pistons for around $100 more than what Summit lists the stock replacement HE pistons for http://www.ws6project.com/user_stor/...oducts_id=4272

Another thing you might want to ask the machine shop about is the rods. Most of the aftermarket/replacement bolts will oval the rods and require a rehoning and oversized bearings. My local machine shops were wanting $175-200 to install ARP rod bolts and do a rehone/recondition on the old rods. For less than $100 more you can get Eagle or Scat I-Beams with ARP bolts included http://www.ws6project.com/user_stor/...index-1-4a.php

Yeah there are better options out there if you want to spend the extra $$$ but as long as you aren't going over 500ish HP the budget stuff should work just fine and not cost much more than HE pistons with reworked factory rods.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Holy moly!! I was looking at those same Probe pistons (P2600F-003) but on summit they are $502!! For $362 I would only be spending like an extra $80-90!! However, looks like you are saying I would need to buy rods too. I have to get all this figured out probably by tomorrow or Monday. I need the block back probably end of next week. So would I need different rods or crazy expensive piston rings???? This is something I need to know. Also these pistons have the -3.0cc valve reliefs what will I need to do about compression ratio?

As far as 500ish HP goes, I may be getting close.. I have LS6 intake, LS6 heads (243 w/ yellow springs.) Full bolt ons, I will be using a cam from Martin Smallwood 226/230 .560/.545 112+2, higher performance melling oil pump, ls7 timing chain.. Then t56 w/ LS7 clutch and 3.73s. However, I am building it just to be a driver not to take to the track. I will probably never even get close to revving out at 6k.. I just want a fun car to drive, maybe shut someone down if they talk smack. It will never see nitrous, blower or turbo.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Well just contacted WS6 store and they said they are removing probe pistons from their website b/c they have such problems getting them they end up cancelling orders after 4-5 weeks of them not arriving. :(

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Yeah WS6 Store is a sponsor on another forum I'm always on (ls1tech) and they usually have really good pricing on stuff. They list those pistons as being available in .927" (floating) and .944" (pressed) wrist pins sizes so you could re-use your stock press fit rods or pick up a set of the stronger LS2/Gen IV floating rods or get a set of aftermarket ones. It just depends on what you want to do and what you want to spend...

The only reason I brought up the rods is because I was seeing a lot of stuff online about how the older rods like your '01 and my '00 were pretty weak and when I talked to the machine shops by me they said the same thing and also brought up the additional cost to get the aftermarket rod bolts to work (rehone/recondition). Double check with your machine shop to see what they say I just didn't want that to be another surprise for you lol.

As far as the piston rings for the Probes it looks like you'd need Clevite/Perfect Circle 315-0037-5 for the 3.902" bore https://www.starperf.com/moly/clevit...m-race-ls1-v8/

ps Summit will usually price match other vendors in case you'd rather buy from them but still get the cheaper price...

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I will try and see if summit will price match the ws6 store. I probably can only afford the pistons though, not a new set of rods..

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Ah man that sucks :banghead:

You might want to double check with Summit to see if they'd still price match WS6 Store. I think they just go to the website to confirm the price and that it doesn't say out of stock. Hopefully they don't call and find out what you just did lol.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Summit will price match and have them in stock!! I called my machine shop guy and gave him the part number to look up and check out for me. Fingers freaking crossed!

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I'm the guy that used the Ford driveshaft in my 4x4 conversion. Technically any driveshaft of the correct length will work if you can find the right U-joints for it. As far as your engine mount pads, I would try to do a little more massaging on them on that top flange to get it to sit flat on the frame. It looks like there is a gap between the frame and flange. Or maybe put a body shim in the gap.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I hope so, I am working on getting my transfer case this weekend then I can see about what crossmember I will have to use. Then I can sit it all in and measure the length of shaft I will need and go to the junkyard and start measuring.

I am still not sure what trans/tcase xmember I need to use though, I plan to use either Np208 or Np241 but do I need a th400 or sm465 or does it matter? I know there are several types.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I picked up my tcase and pedals. I did end up trading the 01 Z71 tcase i had for this NP208 32 spline, I searched his entire inventory and only found 2 32 splines. Both Np208, I found a couple NP241s but were all 27 spline. He took my trade and the pedals were $100. I am happy with that deal.

http://i1223.photobucket.com/albums/...psepe7wkjs.jpg

It fits :)

http://i1223.photobucket.com/albums/...ps4su6xyof.jpg

Now I need to find a xmember!!

Re: Let's Build A 1 Ton Crew Cab 4x4
 

So I think I need an 85-91 4x4 crossmember, supposedly any will work and doesn't matter if 1500,3/4,1 ton... Just to mount it inside the frame. I also need to figure out if I will be using the 2pc driveshaft or not. I prefer not but I have to wait to get it all together to measure the length I will need. Otherwise I will need to trade down a front shaft of the 2 piece that will slide into the 208
tcase.

I didn't even step foot in the shop on Saturday or Sunday due to it being Easter weekend. It was kind of a nice break but I really missed it.

Also need to see about drilling holes in the firewall for the 80s hydraulic clutch master, as well as modifying the floor pan for the NV4500.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I finally got to go out and work on the truck some this weekend. I spent 2.5 hours in the pouring rain searching the junkyard for the trans xmember Saturday morning. I came up empty handed. It was a little disheartening and killed my motivation for the weekend. Luckily I have a few friends with square bodies in this state. I put the dilemma on facebook and within an hour had someone that was gonna bring me one and do some parts swapping on some bench seats of mine.

So that motivated me to pull interior from the truck. Needs a good cleaning.

http://i1223.photobucket.com/albums/...psdvxr3rn4.jpg

http://i1223.photobucket.com/albums/...psbysflond.jpg

http://i1223.photobucket.com/albums/...pseo0f5fgo.jpg

I started seeing about how the taller trans tunnel fits in.

http://i1223.photobucket.com/albums/...psvsdmkmzs.jpg

http://i1223.photobucket.com/albums/...psppiuyqck.jpg

Then I finally got the 6.5 off the tire and onto an engine stand. I wanted to pull oil pan and check out a few more things.

Harmonic balancer wasn't rotted which is a nice surprise, which means my crank is probably still in good shape.

http://i1223.photobucket.com/albums/...psjmy9uxtl.jpg

I do need the starter brace.

http://i1223.photobucket.com/albums/...psdun9k4pe.jpg

Starter was missing a bolt though?

http://i1223.photobucket.com/albums/...psl4uw4vmd.jpg

It looks clean in there! I even see some paint marks still.

http://i1223.photobucket.com/albums/...pskgtkfg3h.jpg

http://i1223.photobucket.com/albums/...psg3xfytsv.jpg

After rotating it over several times and checking every where I only found 1 crack. These are typically cracked a lot worse so hoping this is still good to go, maybe not build up but good to run stock.

http://i1223.photobucket.com/albums/...pswsbywxcu.jpg

So my friends showed up with parts, this was his rig. 454 SM465/241 Dana 60 front & 14bolt ff rear w/ 4.10 gears, crew cab long bed with rear frame shortened and axles moved forward. He is going to eventually build a tube bed w/ headache rack. 37" tires on H1 wheels. I love this thing. It provided me with some more motivation!

http://i1223.photobucket.com/albums/...psrmz4lp1l.jpg

Here are the parts he brought and the elusive xmember!

http://i1223.photobucket.com/albums/...psl7be8bfv.jpg

http://i1223.photobucket.com/albums/...pst5azdl7v.jpg

http://i1223.photobucket.com/albums/...psf4acdp3u.jpg

I also got these fancy seats that were in a choo choo customs or southern whatever truck. Bolt in like factory.

http://i1223.photobucket.com/albums/...pslhudv0au.jpg

Rear seat folds down like a bed.

http://i1223.photobucket.com/albums/...pshvyl9v27.jpg

So I have parts to proceed finally :) It feels so good, motivation is there too! However, all my $ is going to getting my 01 TA back on the road and when parts roll in all my time will be too. I don't plan to stray too far away from the truck though. I want it together!

It looks like I am using the k5 tank in the rear as well, just need to mount it and convert to using diesel.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Completely unrelated to the 88 Crew but I am excited nonetheless!

My block, heads, crank, & pistons are finally out of machine shop prison!

http://i1223.photobucket.com/albums/...psf5qo2w9m.jpg

I ended up with:
3.902 Probe Forged Pistons - PBP-2600F-003
3.902 Ring set - CLE 315-0037-5
LS2 Timing Chain - GM 12646386
Melling Oil Pump - 10295
Engine Pro Gasket Set
TSP 7.4 Hardened Pushrods
Cam from Martin Smallwood - 226/230 .560/.545 112+2
Yellow LS6 Springs
243 Heads of CTS-V
New LS7 Lifters & Trays
New Cam bearings

I still have more parts to buy of course, I will be using the LS7 clutch/flywheel setup.

I hope I can get started on assembling it this weekend. I have to move a lot of parts to my friends shop as well as borrow a dolly to move the car over as well.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I finally got a minute to step foot into my shop this weekend. I started fooling with the tank. Admittedly I did not get far but I was cleaning up and doing a few other things.

However, this shock mount seems to be in the way of the blazer tank. Will it have to be removed? I know I need to install it under frame not over but still seems like it would be in the way.

http://i1223.photobucket.com/albums/...psfxxsaoqe.jpg

In other news. My LS1 shortblock is assembled. I forgot how long it takes when you plastigage everything as well as filing piston rings and what not. Meticulous takes time, which I feel short on these days.

http://i1223.photobucket.com/albums/...psigbwqwly.jpg

http://i1223.photobucket.com/albums/...pssffwhf7o.jpg

On another note my friends lift is now finished being put together and it works!! Can't beat that, we bought it for $450! Some cost was put in for repair parts but still he came out pretty cheap. I hope to test it out soon.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Keep after that Blazer tank and post up what you find. :) I found a Blazer tank over the weekend that I would like to use and have the same concern with the shock mount.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Is there room on the axle to move the mounts outside the frame?

Re: Let's Build A 1 Ton Crew Cab 4x4
 

http://67-72chevytrucks.com/vboard/s....php?p=4288283

This thread may help with the Blazer tank.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

http://i1223.photobucket.com/albums/...pshe9hj6ie.jpg

http://i1223.photobucket.com/albums/...pssgn26h6m.jpg

http://i1223.photobucket.com/albums/...pswfpqa7u9.jpg

http://i1223.photobucket.com/albums/...psilfgutgq.jpg

I can see the light at the end of the tunnel. I miss working on the crew cab though!

I was going to sell a spare driveshaft I had from when I built the 06 ext cab 4x4 Silverado.. Then I noticed that it looked close to the correct length that I may need for this crew cab. Anyone know the measurement necessary for driveshaft for a 4x4 crew cab shortbed? This pic is the 06 driveshaft in front of the 79 4x4 crew cab longbed drive shaft, it appears to be around 12-14" shorter than the 79 driveshaft.

http://i1223.photobucket.com/albums/...psho9wis93.jpg


Also still looking for more info on blazer tank, trying to avoid moving shock mounts.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

This is the route I went.. I already have the frame and axle painted so I didn't want to deal with relocating the shocks. This really wasn't a bad project though. It just took a couple hours.

[IMG]http://i15.photobucket.com/albums/a3...426_200125.jpg[/IMG]

Re: Let's Build A 1 Ton Crew Cab 4x4
 

She is back together just working on the tune. :)

http://i1223.photobucket.com/albums/...pskkupwnyl.jpg

http://i1223.photobucket.com/albums/...psxtzivqwt.jpg

http://i1223.photobucket.com/albums/...psltlgnpbr.jpg

http://i1223.photobucket.com/albums/...pswnhcjmlu.jpg

It's alive!!!

http://i1223.photobucket.com/albums/...psvjatcy8z.mp4

More tuning needed to be drivable will be working on that Saturday. I miss the crew cab!!

Re: Let's Build A 1 Ton Crew Cab 4x4
 

It is driveable now, made it to my 10 yr reunion as planned :) Excuse the mess, been soooo busy.

http://i1223.photobucket.com/albums/...psaicxt7ct.jpg

It is time to get back on this crew cab! My wife has surgery this weds, so hopefully after she heals up and is back on her feet maybe I can make some more progress with this build. I miss it!

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I hope all goes well with the surgery. It will be good to see you working on the crew again. You can catch back up to me and my build :)

Re: Let's Build A 1 Ton Crew Cab 4x4
 

You and me both! Hope it doesn't bankrupt me either!

Yeah I definitely have some catching up to do but at least no rust to fix :). I think the diesel is going to give me the most problems. We shall see.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

hoping and praying all goes well. Keep us updated when you get a chance.

Good job on the car. I missed my 10 year reunion, went to my 20 and everyone seemed the same, this year is my 30 and don't have plans or interest in it. :lol:

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Great job on your car! I also hope all goes well with your wife tomorrow too!