Let's Build A 1 Ton Crew Cab 4x4

[NastyBuzzard]

This is a neat trick!! Especially when you don't have a trans jack!



They are soooo many different types of engine mounts. Trying to pick which ones to use for this 6.5, still don't have it nailed down just yet. It just blows my mind how each set is somewhat different. Somewhere I got a set that doesn't match, one side is taller than the other. Idk if that came from the 6.5 or not.









Had to sit the 6.5 back in to get trans distances and what not for where to mount 4x4 xmember.



Bolted in.







My front driveshaft is about 4-5" too short...



My 06 ext cab short bed drive shaft came up short... By only around 6" or so though so there is hope for a 1 pc driveshaft. I am hoping I can find a driveshaft from a crew cab short bed w/ a 6' bed not a 5' bed bc 5' bed is same length as ext cab short bed. I wan't a nice aluminum one. It may would work for stock height, but I am not sure.



I got these on and test fitted as well. Need some revision work but will work just fine as is with slight hole modification. So cool!!




I got behind this nice square on the way to pick up dinner. I actually like the roll pan, it fits nice.



So much left to do but getting closer and closer for sure!!

[daddyjeep]

That spring hanger turned out nice. I like the nasty buzzard on it.

[NastyBuzzard]

Thank you! It is the first revision, at that angle the head looks like a damn duck but it really doesn't. I will tweak it later but I just wanted to put something there. It was originally a chevy emblem, then GMC (bc this truck is a GMC) but that looked plain.

[daddyjeep]

that's quite the collection of mounts.

[NastyBuzzard]

Originally Posted by daddyjeep

that's quite the collection of mounts.

I have more and none seem to be the same!

[jbclassix]

I want to say that the 3500HD mounts are different than the 1500-3500. also, there is a spacer between the mount and engine block on the 6.5 in the GMT400. somewhere I have the GM part number for the 6.2 mounts. also, did you find a bracket for the starter yet?

[NastyBuzzard]

Originally Posted by jbclassix

I want to say that the 3500HD mounts are different than the 1500-3500. also, there is a spacer between the mount and engine block on the 6.5 in the GMT400. somewhere I have the GM part number for the 6.2 mounts. also, did you find a bracket for the starter yet?

Really? That is interesting for sure. I am having problems getting it to fall in place correctly. I did find the bracket for starter on ebay for like $10-14.

[MTCK]

That's interesting. When I swapped in my L29, it wouldn't drop in. I put the mounts on from the original TBI 350 and it went in as smooth as butter. They were almost identical side by side.

[daddyjeep]

I had to modify my hitch after shortening the frame. I ended up cutting about 3 1/2" off of the back of the frame and since I still don't have a proper 6' bed I am not even sure that is correct. I cut one of the mounting tabs off of the hitch and relocated it a couple inches forward. I also had to clearance the hitch to clear the spring mount. Maybe the blazer hitch would fit better than one for a 1 ton. You'll just have to throw them on the frame and see where you are at.

[NastyBuzzard]

Sounds like a plan, I am sure I will have to modify each one in some way. Especially with my drop down perches, I will have to at least do 2 clearance slots. I just mainly need to know how much to cut off rear. Some people say 4 to 4-1/2 inches and some say 6" b/c that is the difference with the beds.

[wildwilly4x4]

Only spacers any of my diesels have had were just the torque arm plates that go between the block and the motor mount cup.

[NastyBuzzard]

I found out the spacers are only for automatics that go in between the engine mount and block. I think that's exactly what you are talking about with the torque mount plates. So not necessary for my NV4500 so do I need taller mounts or something to make up for that space?

[NastyBuzzard]

Here are the torque plates, I have now found a few people who have done something similar at least 3/4 of them said they needed the 6.2 mounts and either these torque plates or 1/8" spacers.







Trying to see how much I need to cut off the rear... Definitely can't do 6" unless I put the blazer tank in the wrong place, which I freaking hope not! Anyone here done a crew cab short bed with blazer tank or what?











Tinkering with sending unit. For some reason the black hose wasn't plugged up, hope that's the right tube, don't see another way.







Weird that it installs facing the inlet instead of facing the cab.






My baby died on me this morning. Just shut off going down the highway and wouldn't start back up. Codes were for cam position sensor and clutch switch.

Had to push it into someones yard... Pulled a muscle too, shes heavy.



Such a sad sight. Hopefully it is an easy fix, going to beach next week so probably wont have time to fix until after.

[daddyjeep]

Sorry to hear about the car. Hopefully it is just the cam sensor, not a big deal.

Here is the back of my frame minus 3 1/2". Looks just about like yours. I still need to shorten that rear section of my bed to get to proper short bed dimensions, but I can measure from end cross member of the bed to the frame to see where it will end up.

[IMG][/IMG]

[NastyBuzzard]

Yeah it sucked but just glad it isn't a mechanical problem, well still hoping it isn't but I have codes so hopefully that is what it is. I love that thing, but got beach vacation next week so probably gonna put off fixing it until I get back. I need to fix power steering pump anyways so if I am putting it down to work on it I plan to fix another few things.


Yeah yours does look exactly like mine. I just want to get it cut and get my hitch holes drilled and everything else bc I can't lift bed alone and asking people to come put it on just to take it back off will probably piss them off... I have to be selective when I ask for help. So if you can get your bed back on and check to see if it will work that would be great!!

I just have to be sure I can still mount the bumper and the hitch. I dang sure don't want to put bed on then find out I have to drill holes, it is tough enough drilling them as is!

Also, anyone know what type of clutch & flywheel I will need to use with the 6.5/NV4500. Do I get the 6.5 flywheel and clutch package or what? So far it looks like I am going to have to go with the advanced adapters bellhousing and I know they have some restrictions on size of clutch or something. Trying to get final parts list going so I can start projecting when I will have it running.

[daddyjeep]

I'm pretty sure my bumper isn't going back on without some modifications to the brackets. I plan on building a new bumper anyway just because it is fun. I have my bed on the truck, I just haven't shortened the rear yet. I know I need to shorten it 6" so I can measure clearance to the frame tonight.

[NastyBuzzard]

Oh I was confused there for a second, so you still need to shorten yours the 6" so are you going to move your fuel tank up then? B/c if you cut any more looks like you will be cutting into the xmember.

I don't want a fancy home made bumper, I want a stock bumper on mine. I got the big diamond plate OEM one from my 87 that I want to put on there, it is in excellent shape.

[daddyjeep]

the frame is shortened 3 1/2" , but the bed has NOT been shortened in the rear yet. I can measure from the rear cross member of the bed to the end of the frame to make sure I have the 6" of clearance I need.

[NastyBuzzard]

That's right you didn't swap to a short bed you are shortening your long bed, right? I forgot about that. Don't blame you, if I didn't have a short bed and I had good fab skills I would be doing the same. I just happened to have a short bed.

[daddyjeep]

I would have much rather used a short bed, but was under a time crunch and of course financial constraint. I just made what I had work. I was surprised how easy it was to shorten it. It may be more difficult when I do the body work to make it look nice.

[NastyBuzzard]

My problem is that I am running out of stuff to do unless I buy more stuff or start assembling the whole thing. I need the suspension done and all holes drilled in the frame because I am supposed to get my buddy to come weld up a bunch of unnecessary 2wd holes and a few others.

[NastyBuzzard]

Picked up another front driveshaft today. Still coming up short, only had 2" or so left of travel at stock height, hate to see what happens if any flex happens. So still on the hunt for correct front driveshaft. I presume I need one from SM465/Np208 combo since it should be same length as NV4500/NP208 combo.



Forming the tank straps to fit the tank. Need to come up with some cushion material so it won't be squeaking.



After a lot of measuring between my longbed truck and the short bed for this truck. I decided I can get away with just cutting off 4" of the frame. I did move my cross members up the frame towards the cab just shy of 2" than where stock rear xmember was. I want this extra beef for mounting my big diamond plate bumper and the K30 hitch. If I need to cut some off later it will be easier than adding on to it.





Took tank back out for a paint job. Need to paint the straps too as well as the skid plate. Need to figure out cushioning.



Placing the shock mount on other side of the frame mirroring the stock one or DS.





So what shifter do people use for the NV4500 swap for the transfer case. This is stock shifter for NP208/NP241 but I saw Larry used a different kind, maybe from 205? I want it to work as well as match up like his is, do I need the other shifter assy or just the boot?



Also finally took the Dana 60 dust cover off to see if I have the groove as to easily add the locking hubs. It appears I do.. What do yall think? Still trying to track some down. I found these new ones for $100 on ebay, what yall think?

http://www.ebay.com/itm/301826302446...%3AMEBIDX%3AIT

[NastyBuzzard]

Trimmed the trans cover for the NP208 shifter. I hope its the one I will need to use. I am trying to copy kind of what Dirty Larry did with the Polar Bear Suburban. I will have to get my friend to weld up the excess bit that was already cut out.



Cut the shock mount off the passenger side to move it to driver side. I put it in the vise and reshaped it a bit to fit back on the front side of the axle. I need to know what shocks (cheap ones for fitment only really) to buy to set things up so I can have my friend weld the mount back on the axle.




Engine and trans coming out so wanted to take some more measurements. Since they changed with the drop down perches in the rear moving the axle about an 1" forward.


I need a driveshaft about 80" or so long.





Pinion angle doesn't look the best but not too bad, front isn't quite at max height.








Engine and trans coming out for hopefully the final time!!








Clutch kit I plan on buying comes with everything in one go!





Bellhousing I apparently have to buy....





So I need to figure out what lift pump to buy, I don't think I have one. Also need to figure out if I need an inline filter or if my filter in my sending unit will suffice. I am at the point now I need to start ordering parts to keep things going. Although, I will be gone to the beach all this week. Still need to order the locking hub conversion parts as well. Also need probably to do a good bit of work to the dana 60 as well as all new tie rods and what nots. Also need to find right stuff for the hydroboost set up as well as a "good" steering box. I have one but may need a rebuilt. Probably wouldn't hurt to get another jeep steering shaft as well.

I am seriously considering buying new 4" lift springs for up front, I believe these are rough country brand and are super damn stiff. I also need to order some longer shackle sides/hangers whatever you call them. Something better than the home made temporary ones that I did to get the spring eye off the frame.

[MalibuSSwagon]

Why do you have to buy that bellhousing? Did you try fitting the front driveshaft while everything was in the truck?

[daddyjeep]

I know that you are already done with the shackle on the rear of the springs, but maybe you should just revisit that instead of building the big drop brackets for the front. I have seen shackle hangers frenched into the frame before on LCG Jeeps so there is no reason you couldn't come up with something to fit your needs. Just food for thought.