Bought my old K5 back, now receiving a 5.3 swap...

[Ford Assassin]

Hey guys, been gone a few years after I sold my '69 C10 short bed. Anyway I bought this K5 in the Summer of 1999 from the original owner. It was bone stock except a 4" Rancho lift, 4.11 gears, and a rebuilt/beefed 700R-4. I bought a set of 15x10" M/T Classic II's and Dunlop MT 33x12.5x15's within a few days. Other than the 208c needing a shifter fork (replaced the chain at the same time), it was trouble free. I bought a worn 350 short block in the Spring of 2007 and rebuilt it with a set of flat tops and brand new iron GM heads. A few months later a buddy offered me a straight across trade for his '69 C10 and I accepted (big mistake) .


A few months ago he started asking me if I was interested in buying it from him. Well a month ago I got my pennies saved up and bought it back. He warned me of a slight misfire it was having underload, but I chocked that up to be a bad spark plug or wire. Several dollars later after replacing the entire fuel and ignition setup, still had the mis...

Since I used to do LS swaps part time I usually had a spare LS motor or two laying around.. So this K5 is getting a new modern powerplant with the modern EFI. I am going to retain the 700R-4 using a TV cable bracket adapter kit from BowTie Overdrives. Later when funds permit I might swap out the older 700R-4 for a modern 4L60e (electronic controlled via PCM) and a passenger side drop 241c transfer case.

The 5.3 is from a 50,000 mile 2002 Silverado 1500 2WD. It will remain stock except for a mild cam/spring/pushrod swap from 2003 Corvette LS6. I am still on the fence on whether I want to go though the initial cost and expense of doing long tube headers (shorties and block huggers are not worth the expense vs power gains). I might just use stock manifolds and save for a small turbo setup down the road. Time will tell.

I will also be buying an aftermarket AC bracket for a Sanden 508 compressor so I can have my creature comforts in hot Bakersfield Summers.

That's it for now.

Thoughts, comments, and/or questions? Post'em up!!

Thanks guys!!
Posted via Mobile Device

[68Timber]

Sounds like a solid plan. Post some pics.

[Ford Assassin]

These are before and after shots of a few days after I bought it (rims and tires added) and then a few weeks ago...

[68Timber]

Did you do the full vert conversion?

[Ford Assassin]

Originally Posted by BRUISER

Did you do the full vert conversion?

Yes and no.

I bought the full convertible top, windshield frame, and door pieces (all from different K5's) over the years I owned it the first time. It was always my goal to do the full convertible conversion 'someday'.

I gave him the parts whem we made the trade and about a year after that he paid a body shop to do the conversion, add a factory style 4-point roll bar, and throw a paint job on it.

He didn't add the extra floor bracing though so I welded in 3x3" box steel under the floor and inside the rocker panels. It seemed to help alittle, but I still don't care for the squeeks and groans the body makes.

[68Timber]

Sounds like you're on top of it. Good looking truck, the swap sounds sweet.

[Ford Assassin]

I forgot to mention when I still owned the truck the first time I blew up the factory G80 option (posi) Eaton Gov-Loc 8.5" 10 Bolt and instead of rebuilding another weak rear end, I started over with a 9.5" 14 Bolt from a '89 3/4 Ton 'Burb with factory 4.11 gears and a Gov-Loc posi. Luckily the Gov-Loc in the 14 Bolt is much stronger and works alittle better than the 10 Bolt counterpart. Plus it has HUGE rear 13x3" drums so it brakes rather well. I had the factory 8 lug axles welded up and redrilled for the 6 lug pattern. Drums were just redrilled.

Originally Posted by BRUISER

Sounds like you're on top of it. Good looking truck, the swap sounds sweet.

I tend to change my mind alot on the direction I want to take.

Like I have already changed my mind about the 4L60e/NP241c down the road. Instead I am going to put a 4L80e so I can actually tow in overdrive without worries and it'll stand up to a turbo if I add one later. Plus it'll allow me to retain my stock NP208c transfer case just by changing the input shaft (on the T-Case) from the 1/2 ton 27 spline to the 3/4-1 ton 32 spline. The only downside is the 100 lbs extra the 4L80 weighs over the 4L60 and it will 'eat' alittle more power too, but I am not doing this build/swap to take a flyinh brick down the quarter mile either.
Posted via Mobile Device

[Hoods69BadBowTie]

Awesome looking k5 looks like its going to be a fun project. Can't wait to see some more pics and progress. Have fun and keep up the good work.

[Ford Assassin]

Update:

Had a 4L80e build from the bottom up, all new parts/electronics, Trans-Go HD2 shift kit, etc. Builder sats it good to at least 1000HP and will tow anything I want, even in overdrive. Converter is a GM reman, 2000 stall.

I also bought a '02-'04 LS6 cam/springs/pushrods and swapped them prior to installing in the K5.

I went ahead and bought some eBay F-Body stainless steel long tube headers. Both sides need mods to work correctly, but nothing major.

Although extreme overkill for this engine, I bought some 8.1 litre marine injectors (42 lbs). Incase I ever turbo this motor, at least I will be set with good enough injectors for my power goals.

I had to find another NP208c with a 32 spline input shaft to mate up to the 4L80e since the first year 4L80e was 1991 and the last year for the NP208c was 1987 (at least with GM). I had to knock out an inch from the rear driveshaft, but the front will work.

Still have a bunch of little things to do, but it is progressing nicely.

More updates to follow!

[Ford Assassin]

Okay guys, motor and transmission are installed. 95% of the harness is wired up.

I had to modify the F-Body headers to work. The driver side just needed the collector pie cut since these headers tend to 'toe out' (was hitting the spring shackle). The passenger side was also hitting the shackle, but on the actual tubes. So I had to pie cut all 4 primary tubes from the bottom in order to 'swing' the header away from the shackle, but still allow room for the starter too.

[WOOS1]

Any updates on this project? It is looking good. What did you do to control the trans? a stand alone or did you add a VSS sensor to the 208?

[Ford Assassin]

Originally Posted by WOOS1

Any updates on this project? It is looking good. What did you do to control the trans? a stand alone or did you add a VSS sensor to the 208?

I should be done with it by the end of this weekend. I ended up replacing 90% of the fuel system and just need to finish a bunch of little things now.

I am using a PCM from a 2002 Silverado, with some slight tuning tweaks it'll run the 4L80e.

The 4L80e has a VSS already built in to the side of the case, not like most other GM trans with the VSS located in the tailshaft. I could buy a pass-thru VSS for the NP208c also, but I am not going to be doing alot of driving in 4-Lo where I'd be concerned of the PCM receiving the wrong actual MPH (which is mostly for fuel trims anyway).

[WOOS1]

Please keep us posted. I have a 1991 Blazer I am wanting to do the swap in. I have a LQ9 that needs rebuilt along with a harness and a pile of parts. But I have been unable to locate the elusive 3/4 ton 1991 suburban transfer case with the VSS sensor as I am a little scared of a 6.0/4L60E combo. I am thinking I might run one of the Holley management systems to run it.
Posted via Mobile Device

[Ford Assassin]

Originally Posted by WOOS1

Please keep us posted. I have a 1991 Blazer I am wanting to do the swap in. I have a LQ9 that needs rebuilt along with a harness and a pile of parts. But I have been unable to locate the elusive 3/4 ton 1991 suburban transfer case with the VSS sensor as I am a little scared of a 6.0/4L60E combo. I am thinking I might run one of the Holley management systems to run it.
Posted via Mobile Device

Just get the 32 spline input for your NP241c and reuse the rest of the transfer case. Any decent trans shop should have extras laying around.

The Holley setup is nice, but overpriced IMO.
Posted via Mobile Device

[WOOS1]

I have looked ordering a new input shaft. My T/C case has issues and will not go into 4 Low so I figured to just get a different one. And as for the Holley set-up, I just may be able to get a deal on it.

[Ford Assassin]

Originally Posted by WOOS1

I have looked ordering a new input shaft. My T/C case has issues and will not go into 4 Low so I figured to just get a different one. And as for the Holley set-up, I just may be able to get a deal on it.

Is your NP208c from the same truck with the SM465?

If so, you already have a 32 spline input shaft in your NP208c (same with the TH400 models).

I'd be willing to bet your 4-Lo issues are due to a bent or split shifter fork (common on factory stock NP208c). I've had it happen a few times myself. The shifter fork is about $20 brand new and of course replacing the chain is ALWAYS a good idea since you are already there.

[WOOS1]

Actually it is by the vehicle in my sig. I have 5 of the square bodies now. I want to do the swap in a 1991 K5 blazer with a stock 5.7/700R4/NP241. I do still have the truck in the sig and I also have an extra NP208 from a SM465.
Posted via Mobile Device

[Ford Assassin]

Another update...


The truck has been running for over two months without fail, 18-19 mpg highway, 12-13 towing on the highway, 14-15 city.

But I have found out that I have lost all interest in off-roading....

As such I am not interested in climbing into this thing forever, so I have decided to convert to 2wd.

I already bought a front frame section w/suspension along with a 8.5" 10 Bolt with 3.42 gears (open) and rear spring hangers.

I already have a brand new set of gray Boss 338 20x8.5" & 20x10" I bought for another project that'll go to the K5 instead. I bought a set of used, but nice tires today for $200 mounted/balanced, 245/45/20 for the fronts and 275/40/20 for the rear.

I also bought a DJM axle flip kit for the rear, says its good for 5-6" of drop, but I plan to retain as many (or all) of my existing rear leaf springs because when towing it doesn't sag more than an inch. This is something I want to keep. If I need more rear drop, there are always drop shackles too.

I have already tore the front suspension completely down, going to replace the old rubber bushings in the control arms and sway bars with poly-urethane. I am also going to replace the ball joints (still the originals) while I have everything apart.

I am on the cheap so I am just going to cut a coil (using a cut off wheel) to set my ride height, will replace with drop spindles down the road.

I have to have the stock 1.25" rotors modified to work with my Boss wheels too, no biggie, just some minor work on the lathe.

[onedayjake]

Good man! I want to see your progress as I plan on doing the very same thing soon! I had a 74 Jimmy lifted with 35's and loved it but never took it off road and got tired of climbing up and jumping out. I have a line on a mid 80's K5 that I'll swap all of my 2wd Suburban stuff to and an L33 that just needs put back together.

[bowtieguy79]

Interested to see what all is done from going 4x4 to 2wd. Been thinking about this swap on my 78 K5.

Post up some progress pics!

[onedayjake]

Here was my first inspiration.
http://67-72chevytrucks.com/vboard/s...d.php?t=168231

[Ford Assassin]

Originally Posted by onedayjake

Here was my first inspiration.
http://67-72chevytrucks.com/vboard/s...d.php?t=168231

Yup. Read it months ago, which is why I know it can't be too hard.
Posted via Mobile Device

[68Timber]

Sounds sweet - share all the pics you can.

[Ford Assassin]

I received my DJM flip kit and I am not impressed with the contents, especially for almost $100. So I am going to return the DJM kit and I buy some universal springs perches (for 3.00" axles tubes) instead for $10 and will fab my own flip kit by welding these directly to the axle tubes and buying new u-bolts and plates (can't use my old ones since I had a 14 bolt in the rear.

I also pulled out the front diff and suspension yestersday, I am pretty sure I have it sold to a guy with a '90's Chevy 4x4 that wants to go SFA.

[onedayjake]

Nice! Take pics please as you go. That other thread had not so great pics, maybe they were from an old cell phone, lol.