1990 Suburban LQ4/4L80E/D60/14Bolt swap

[KeithT712]

Along the way I checked craigslist and similar sites religiously in hopes of finding a complete donor truck, I could have just found and pulled a junk yard motor but I wanted a complete truck to take my time and work with. Eventually I found a lowish mileage (~150k)2002 Chevy 2500hd 6.0 auto posted online. the body was rough and the idle was off (intake gaskets) but the truck had been a fleet maintained vehicle for a plumbing outfit its whole life. Another trip across vermont in a flat bed and it was at its new home.

Eventually when the time was right the motor transmission and transfer case were pulled out, valve covers were pulled and the inside of the motor appeared clean but was still stripped down and block send out to be checked and hot tanked along with new bearings and cylinder hone and crank polish.
Ended up selling the transfer case out of the truck for $500
seeing how driver side drop transfer case wasn't going to work with my gm 60, and I'd prefer not running a ford axle on this one

[KeithT712]

Can't seem to figure out why the pictures keep posting upside down and sideways but still we'll push on

Deciding on what transfer case to put behind the 4l80e was easy thanks to Off Road Design and their 4l80e/np205 adapter getting the best of both worlds I went with a 205 built specifically to be bolted right up (with a speed sensor that would plug right in to the ls harness also) as well as a twin stick shifter set up (mostly because I've always wanted to run one of them)

I'm sure there are other options that can be done, just 205 is what is run in the mud burb so I see no reason why a tow rig cant have one too. The first hurdle with this setup was needing the tranny crossmember and mounts out of and earlier truck (pre 85 i believe) that would have come with the 205, which was easily found either from local yards or in this case eBay for a clean one

Next was to re assemble the front and rear axles and place them under the springs

[KeithT712]

Rebuilding the axles went fairly smoothly for never having touched a dana 60 or 14 Bolt before, other than maybe a wheel bearing or two. Front end was first! Again Off Road design was the answer for differential rehearing kits (priced around and seemed to be the best prices) as well as all wheel bearings, Kingpin rebuilds etc.

I spent a good amount of time doing research on brake options for the front end, I wanted something that would be an upgrade over the original brakes and with the idea of occasionally pulling a trailer with a full size SUV I wanted them to be BIG

Torq Motorsports was the answer! Their setup lets you run the 2009+ Dodge ram 3500 brakes with the ~14.5" rotors and dual piston calipers, overall install went fairly easy, brake parts can be picked up at any local parts stores just can still be pricey caliper rotors and good set of pads ~$400 But of course there was a hurdle as there always is. Best option for caliper bracket bolts was from the dealer part no. 06509456AA total price from local dealer ~$10 and 1 day waiting period. When I went to put them in found they were a touch too long, so all 4 were cut down slightly and cleaned up, unfortunately it also requires the hubs be machined down in order to slip the rotors on from the outside which is manageable just more work

On a side not as i've skipped right over it, back around christmas time i managed to catch the black friday deals from Off road design on a 2wd PSC steering box and crossover steering set up which can be seen on the frame

[KeithT712]

Small progress on the burb last night...

Rear end finished bolting up spindles and hubs cleaned and ready to go on, just waiting on brakes.

When i picked up the rear axle it had no name disc brake brackets on it running 80s k20 front brakes so thats the setup that stayed, total parts cost for brand new calipers, rotors and good pad set ~$140 (much better than price for fronts)

Downside to this setup is loss of park brake but that will be addressed at a later date, at this point it looks like the answer is transfer case brake. Curious if anyone has any experience with running one on their rigs