Dang it...
Something to add to the spare parts box.
CK5
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1 month to 8.1 swap, then another month to Nv4500 swap
- Thread starter #Burbslut
- Start date
87 V20 Burb- 6.2 Diesel to 8.1-Th400 to Nv4500
I got around a month to complete, then a 800 mile drive. and then a 2300 mile roundtrip
Something to add to the spare parts box.
Which thread? I feel like I have read them all...
Found the post. Larry pulled them since he couldn't keep them from leaking.
Drives me nuts….I hate leaks! The nice thing about having everything painted and clean is it is so easy to keep it that way. Its been 2 years and about 10,000 miles since I redid my NV4500 with a round 205 and even after a few desert trips it still looks as clean as it does in the picture below....well, after a carwash when returning from a trip.
The stupid Geno's Garage NV4500 PTO plate trans coolers would never stop leaking so I yanked them off before this past desert trip. Overpriced garbage
Other 205’s I’ve built I used farm store Case tractor red. It’s a bit bright but this oil based tractor paint seals it up nicely. This one didn’t leak anywhere but I still like the primer red with clear better
The diesel guys don’t generally run them either and they are towing heavy loads and//or running crazy power.
Nv4500 swap is a few steps closer. The Off Road Design high-clearance crossmember with their hd mounts wouldn’t let the motor tilt back enough. I had to loosen the mounts from the pad, but it still didn’t tip back enough. Solution? Cut a few slices in the floor pan to allow the transmission to tip up and fit the shift tower. I’m thinking I’ll be on the hunt in the future for a removable hump and replace the molded in one.
A few things that I came across. 1st off. I didn’t need to re-drill the the transmission crossmember holes. The nv4500 and th400 also used the same crossmember. The passenger side slave cylinder seems to clear everything. It’s a tight fit, but it all mounted up.
I spent most of the day taking the transmission in/out trying to align everything and cutting the floor.
I’m sure my kids learned a few new words.
I also had to take the dash back apart to remove the master cylinder to pedal assembly rod because the stud decided to start spinning. I’ll tack weld it tomorrow and hopefully wrap up this swap.
Sometimes you gotta build your dream setup yourself. 
8.1/nv4500/208 on Won Tons.
A few things that I came across. 1st off. I didn’t need to re-drill the the transmission crossmember holes. The nv4500 and th400 also used the same crossmember. The passenger side slave cylinder seems to clear everything. It’s a tight fit, but it all mounted up.
I spent most of the day taking the transmission in/out trying to align everything and cutting the floor.
I’m sure my kids learned a few new words.
I also had to take the dash back apart to remove the master cylinder to pedal assembly rod because the stud decided to start spinning. I’ll tack weld it tomorrow and hopefully wrap up this swap.
Sometimes you gotta build your dream setup yourself.
8.1/nv4500/208 on Won Tons.
I’m like my own worst enemy sometimes.
My np208 in my 87 has been starting to howl louder in 4Lo. Rather than just swapping in another 208, I knew my friend just scored on a round pattern 205. A few trades and some $$$ later, I brought it home.
I’m not sure if this one will get a full rebuild or just swap the input shaft to a short version and put it in.
So I have a few options.
A. Rebuild it and put a short input shaft into it.
($400) this would require a different rear driveshaft($150-$400)because the 208 is a slip yoke.
B. Swap a short input shaft($150) different rear driveshaft($150-$400)
C. Swap in short input shaft($150) and swap rear output to slip yoke(free used parts), and use the stock rear driveshaft.
I just remembered. All of these options require some type of custom np205 shifter because the nv4500 has provisions for 208/241 shifter.
I’m pretty sure that the 208 will be going back in temporarily. I don’t have the time to figure this out before Monday. I’m heading to the Canadian border for a 4x4 competition. Mountain Havoc.
My np208 in my 87 has been starting to howl louder in 4Lo. Rather than just swapping in another 208, I knew my friend just scored on a round pattern 205. A few trades and some $$$ later, I brought it home.
I’m not sure if this one will get a full rebuild or just swap the input shaft to a short version and put it in.
So I have a few options.
A. Rebuild it and put a short input shaft into it.
($400) this would require a different rear driveshaft($150-$400)because the 208 is a slip yoke.
B. Swap a short input shaft($150) different rear driveshaft($150-$400)
C. Swap in short input shaft($150) and swap rear output to slip yoke(free used parts), and use the stock rear driveshaft.
I just remembered. All of these options require some type of custom np205 shifter because the nv4500 has provisions for 208/241 shifter.
I’m pretty sure that the 208 will be going back in temporarily. I don’t have the time to figure this out before Monday. I’m heading to the Canadian border for a 4x4 competition. Mountain Havoc.
Coming along nicely. Have a 4500 swap in my future when I get the engine done. Taking lots of notes!
I'm trying to make sure all the stuff is documented.
Success!
I drove it for the first time this evening. I was gentle shifting gears, I want to break in the flywheel. The 34” tires combined with the 3.73 gears and deep first gear is a nice combo. I didn’t get a chance to go on the freeway but I’ll get to that tomorrow.
There were a few things that I was worried about but it seems to be fine. The nv4500 is about 1/2 shorter than my th400 so my slightly too long rear driveshaft and too short front. Worked out perfectly. That means I don’t have to have the driveshaft redone until I’m ready to put the 205 in.
One thing that’s odd. I must have unplugged something behind the dash. My door locks are not working now.
any hints?
I drove it for the first time this evening. I was gentle shifting gears, I want to break in the flywheel. The 34” tires combined with the 3.73 gears and deep first gear is a nice combo. I didn’t get a chance to go on the freeway but I’ll get to that tomorrow.
There were a few things that I was worried about but it seems to be fine. The nv4500 is about 1/2 shorter than my th400 so my slightly too long rear driveshaft and too short front. Worked out perfectly. That means I don’t have to have the driveshaft redone until I’m ready to put the 205 in.
One thing that’s odd. I must have unplugged something behind the dash. My door locks are not working now.
any hints?
Sorry, been busy at work. The recent one was from oreilly PN: 34/78PLT
https://www.oreillyauto.com/detail/...42695/1989/chevrolet/v1500-suburban-4wd?pos=0
Thanks. I was curious about the cost and warranty. I’m getting a better deal with the same warranty luckily. I put them on the tester and they measured around 1000amps each.
Wrapped up the nv4500 swap and got the interior back in it. I busted my drivers side a pillar trim, so I’m on the hunt for a replacement in blue.
I ended up going a different route with the shifter boots than anticipated. I tried to trim down the stock np208 shifter housing but once I realized that I’d have to cut a few inches into the upper left side, I abandoned that idea.
So I switched up to my JB Fab boot setup. Then abandoned that idea too. It would work just fine, but it left a big un carpeted section uncovered. That just wasn’t going to work for me visually. I don’t want to look at the floorboard or insulation. Or but new carpet right now.
So I went with plan C. I had a few random boots from parted out trucks and burbs. I picked the best looking and fitting together versions and just went for it. I plan on replacing the hump, carpet and going to a different t case shifter. So it will do for now.
I ended up going a different route with the shifter boots than anticipated. I tried to trim down the stock np208 shifter housing but once I realized that I’d have to cut a few inches into the upper left side, I abandoned that idea.
So I switched up to my JB Fab boot setup. Then abandoned that idea too. It would work just fine, but it left a big un carpeted section uncovered. That just wasn’t going to work for me visually. I don’t want to look at the floorboard or insulation. Or but new carpet right now.
So I went with plan C. I had a few random boots from parted out trucks and burbs. I picked the best looking and fitting together versions and just went for it. I plan on replacing the hump, carpet and going to a different t case shifter. So it will do for now.
Where’s the better deal? I’d like to note it for next time.
I work at a small mom and pop parts store in Capitola. I get a good deal on Deka batteries. The problem is that I'm quitting in 3 weeks to go a different direction.
I just got home from a 2300 mile round trip. 22ft trailer in tow. No major issues to report. Just another collector gasket failure and the header flange gaskets started to leak. I guess I’ll drive the tbi burb until I fix it.
I had a heater core scare. I was running it hard and then parked it. I saw coolant on the Pass floorboard and got mad. I’ve changed that thing once a year for now he past three years. I ignored it while I wasn’t driving it for a few days, but on the rip home. I saw a puddle on the pass side again. Luckily I found the heater hose clamp was loose at the heater core. I tightened it and after putting down another 700 miles. No leak or smell.
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I had a heater core scare. I was running it hard and then parked it. I saw coolant on the Pass floorboard and got mad. I’ve changed that thing once a year for now he past three years. I ignored it while I wasn’t driving it for a few days, but on the rip home. I saw a puddle on the pass side again. Luckily I found the heater hose clamp was loose at the heater core. I tightened it and after putting down another 700 miles. No leak or smell.
View attachment 343222
View attachment 343226
So that's success overall!
Cool!
Cool!
Did you figure out the door locks? The relay module is somewhere above the gas pedal. Maybe you unplugged it?
I did not get it fixed yet.
Chances are that I did unplug it when moving everything around. I needed the space for the clutch pedal assembly and the drive by wire pedal. I'll have to look and see what I missed, and or took out on accident.
Thanks.
I bit the bullet and ordered up a ARP 12point collector bolt kit. I need the smaller head on the nuts and bolts because I’m not able to get a open or closed end wrench on them to tighten the collector up. I was going to order the stage 8 setup but wasn’t sure if they were going to clear the pipes. I had a set of 12 point bolts for a intake manifold and they seem to fit well. I couldn’t find smaller headed nuts so the arp setup should work.
I had considered ordering the stage 8 header bolt setup but I haven’t had the problem of those backing out(yet). I’ll be tearing into the exhaust this weekend. Remflex header gaskets and copper collector gaskets. I really want to put bigger exhaust on it. At the moment, it’s the tiny stock pipes with Magnaflow mufflers. I’m having a tough time finding a exhaust shop I trust at a decent price so it will have to wait. I really would like to run 3” all the way out in the stock routing.
I had considered ordering the stage 8 header bolt setup but I haven’t had the problem of those backing out(yet). I’ll be tearing into the exhaust this weekend. Remflex header gaskets and copper collector gaskets. I really want to put bigger exhaust on it. At the moment, it’s the tiny stock pipes with Magnaflow mufflers. I’m having a tough time finding a exhaust shop I trust at a decent price so it will have to wait. I really would like to run 3” all the way out in the stock routing.
I don’t think I have ever waited more than two days when I order anything from Summit racing. I made sure that the closest store in Reno had what I needed. I was shocked that I didn’t get them yesterday since I placed the order on Thursday. Delivery date is Wednesday! I guess I’ll get to other things.
I went and picked up my buddy’s memorial truck. I try to help out the parents as much as possible. I’ll be tearing out the motor, transmission and t-case. The parents bought the motor that my friend always wanted, so my tired old stock 350 that I gave them(and installed) will be coming out. The th350 that’s in it, is slipping and the 203 just needs to go away. The parents bought a 425 hp stroker for it and I am supplying a good used 400/205 combo. I was hoping to install everything myself, but I am off to a 8 week training course and I won’t have time to do it before the memorial trip.
Check out that 14bff Hickey cover!
I went and picked up my buddy’s memorial truck. I try to help out the parents as much as possible. I’ll be tearing out the motor, transmission and t-case. The parents bought the motor that my friend always wanted, so my tired old stock 350 that I gave them(and installed) will be coming out. The th350 that’s in it, is slipping and the 203 just needs to go away. The parents bought a 425 hp stroker for it and I am supplying a good used 400/205 combo. I was hoping to install everything myself, but I am off to a 8 week training course and I won’t have time to do it before the memorial trip.
Check out that 14bff Hickey cover!
