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1987 LS swap burban 5.3/4l60E/NP241C

8

87burbman

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May 20, 2015
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Hey everyone. My 700R4 is basically dead, i've been doing a ton of research trying to prepare for the swap and had a couple of questions on a few items I'll need. I'm picking up a whole 2002 1500 4x4 on Saturday so anything from the donor I will need I will have. I plan on doing the whole swap for under 2k (hopefully well under) after parting out the rest of the truck and selling my drivetrain as it is. The 350 is running like crap as well so why spend the money when this option is out there! I am not used to these trucks by any means. I also have a built 84 Long bed on 1 tons and 42s and an 85 K20 plow / landscape rig. I NEEDED the burban for a growing family. I know I know, great excuse.

Here is what I know

1. 2002 5.3 DBC

2. Matching 4l60E

3. 1990 NP241C transfer case and gauge cluster for VSS

4. AC Delco EP381 which will fit into my current tank setup. Wix 33737 filter. I still have to pinpoint all of the fitting and lines I will need to use

5. Wiring harness and PCM will be sent out unless someone can convince me to do it myself. Not sure I have the time as I will be taking time off from work just to do the swap

Things I don't know.....

6. What motor mounts will I need with this engine/tranny/tcase setup in order to maintain my current driveshafts? Through my research the setup i'm going with should all bolt together directly and theoretically in the stock locations....depending on the mounts I use. I know dirty dingo is adjustable but notching of the front cross member is needed. Any way to avoid doing that with another set of mounts? I see a significant number more 2WD swaps than 4wd which don't have this issue.

7. What manifolds / headers will work with the above motor mounts?

8. I will be using this AC setup unless the compressor is too small for a suburban with rear AC. Does the size of the compressor matter? If I need a bigger compressor I will have to dish out for one of the more expensive solutions. http://www.maliburacing.com/forum/viewtopic.php?=34&t=79059

9. I will be reusing my stock radiator unless it is better to use the one that comes with the 5.3. I see most people reusing their current but most people don't end up having the donor truck. Should I be purchasing an electric fan setup or can I maintain the stock?

Thanks for any help in advance. I've read through a ton of threads front to back but have been having trouble tracking down this exact setup and answers. It seems noone is running my exact setup that I can track down and has actually finished updating the thread. And unfortunately I don't have the fabrication skills I wish I had :dunno: aka zero.

On a side note, i purchased my burban in Addison / Jackson Mighigan. My searchtempest addiction got the best of me and next thing you now my brother and I are on a flight from Boston to Detroit. Anyone from that area recognize the truck?:D

263dahj.jpg
263dahj.jpg
 
87burbman said:
Hey everyone. My 700R4 is basically dead, i've been doing a ton of research trying to prepare for the swap and had a couple of questions on a few items I'll need. I'm picking up a whole 2002 1500 4x4 on Saturday so anything from the donor I will need I will have. I plan on doing the whole swap for under 2k (hopefully well under) after parting out the rest of the truck and selling my drivetrain as it is. The 350 is running like crap as well so why spend the money when this option is out there! I am not used to these trucks by any means. I also have a built 84 Long bed on 1 tons and 42s and an 85 K20 plow / landscape rig. I NEEDED the burban for a growing family. I know I know, great excuse.

Here is what I know

1. 2002 5.3 DBC

2. Matching 4l60E

3. 1990 NP241C transfer case and gauge cluster for VSS

4. AC Delco EP381 which will fit into my current tank setup. Wix 33737 filter. I still have to pinpoint all of the fitting and lines I will need to use

5. Wiring harness and PCM will be sent out unless someone can convince me to do it myself. Not sure I have the time as I will be taking time off from work just to do the swap

Things I don't know.....

6. What motor mounts will I need with this engine/tranny/tcase setup in order to maintain my current driveshafts? Through my research the setup i'm going with should all bolt together directly and theoretically in the stock locations....depending on the mounts I use. I know dirty dingo is adjustable but notching of the front cross member is needed. Any way to avoid doing that with another set of mounts? I see a significant number more 2WD swaps than 4wd which don't have this issue.

7. What manifolds / headers will work with the above motor mounts?

8. I will be using this AC setup unless the compressor is too small for a suburban with rear AC. Does the size of the compressor matter? If I need a bigger compressor I will have to dish out for one of the more expensive solutions. http://www.maliburacing.com/forum/viewtopic.php?=34&t=79059

9. I will be reusing my stock radiator unless it is better to use the one that comes with the 5.3. I see most people reusing their current but most people don't end up having the donor truck. Should I be purchasing an electric fan setup or can I maintain the stock?

Thanks for any help in advance. I've read through a ton of threads front to back but have been having trouble tracking down this exact setup and answers. It seems noone is running my exact setup that I can track down and has actually finished updating the thread. And unfortunately I don't have the fabrication skills I wish I had :dunno: aka zero.

On a side note, i purchased my burban in Addison / Jackson Mighigan. My searchtempest addiction got the best of me and next thing you now my brother and I are on a flight from Boston to Detroit. Anyone from that area recognize the truck?:D

263dahj.jpg
263dahj.jpg
Click to expand...




Looks like a nice suburban. Good job on finding a decent donor truck.

I'll respond in order.

1. cool

2. cool

3. You may have to get a clocking ring to get the t-case to fit with the 4l60 adapter, simply bolting the two will tell you if you do.

4. The corvette filter is not needed with the return style fuel rail on the 2002 engine. it is ONLY needed on 04 up returnless systems. Just reuse the stock fuel lines and filter and adapt to the 5.3 fuel rail.

5. If you are good with wiring diagrams do it yourself, of you're not then send it out.

6. AFAIK the only way around notching the crossmember is getting a custom crossmember from DIY or pacific fab or changing the oil pan. Adapter brackets that reuse the 350 style mounts are sold by about everybody and are easy to install and adjust, just make sure to buy poly motor mounts, rubber mounts are junk and will cause you grief. Everything else "should" line up in the original positions. Results seem to vary.

7. I don't of any off the shelf headers that work consistently. A non-egr truck manifold will work on the passenger side with very minor trimming, the driver side truck manifold will require cutting to clear the frame. I believe a LS1 manifold works ok.

8. I've never seen that done before but it looks like it should work and you'll be able to reuse your existing compressor and possibly most of your lines.

9. Reuse your stock radiator if it is in good condition. The 5.3 radiator is wider and will require fab work to install. Use the 5.3 clutch fan. You should be able to reuse the burb shroud as well. Electric fans can be done and controlled by the PCM but are kind of a PITA especially when a clutch fan works so well. Make sure to plumb the small coolant hose off the heads to either the water pump inlet or the lower radiator hose.
 
bigblock72 said:
Looks like a nice suburban. Good job on finding a decent donor truck.

I'll respond in order.

1. cool

2. cool

3. You may have to get a clocking ring to get the t-case to fit with the 4l60 adapter, simply bolting the two will tell you if you do.

4. The corvette filter is not needed with the return style fuel rail on the 2002 engine. it is ONLY needed on 04 up returnless systems. Just reuse the stock fuel lines and filter and adapt to the 5.3 fuel rail.

5. If you are good with wiring diagrams do it yourself, of you're not then send it out.

6. AFAIK the only way around notching the crossmember is getting a custom crossmember from DIY or pacific fab or changing the oil pan. Adapter brackets that reuse the 350 style mounts are sold by about everybody and are easy to install and adjust, just make sure to buy poly motor mounts, rubber mounts are junk and will cause you grief. Everything else "should" line up in the original positions. Results seem to vary.

7. I don't of any off the shelf headers that work consistently. A non-egr truck manifold will work on the passenger side with very minor trimming, the driver side truck manifold will require cutting to clear the frame. I believe a LS1 manifold works ok.

8. I've never seen that done before but it looks like it should work and you'll be able to reuse your existing compressor and possibly most of your lines.

9. Reuse your stock radiator if it is in good condition. The 5.3 radiator is wider and will require fab work to install. Use the 5.3 clutch fan. You should be able to reuse the burb shroud as well. Electric fans can be done and controlled by the PCM but are kind of a PITA especially when a clutch fan works so well. Make sure to plumb the small coolant hose off the heads to either the water pump inlet or the lower radiator hose.
Click to expand...

Thanks for the input BigBlock72.

I picked up the transfer case Friday morning and the truck Saturday morning. Big items are out of the way!

Looks like ill be using the stock radiator and using the 5.3 fan. I see a lot of companies / people doing the wiring changes adding in the electric fan wiring. Seemed common, but I guess it depends on the application.

I've decided to send the wiring out, maybe the same place I get the PCM reflashed. Still doing research deciding who I want to go with.

I'll be going with the dirty dingo mounts and will put up with the crossmember changes needed. Mainly due to the fact they are adjustable and I want to be sure all other linkages line up as well as the driveshafts. If I feel like spending the money I may get an aftermarket crossmember. Thanks for the recommendation on the poly mounts.

I've heard good things about the 2010 Camaro manifolds, ill more than likely be grabbing a set of ebay shortly as I continue to get everything needed.

As for AC, im still weighing options out. I'd like to complete everything while im in there if time allows. I don't like leaving items open on a build. I rarely find the time to go back and finish them.

My open list of items is luckily getting smaller. The below does not include what needs to be purchased.
1. I need to shore up the fuel system pieces i'll need and get those ordered.
2. Decide where to send my wiring / PCM or buy an already built harness. pros/cons vs. cost
3. Decide an AC route, which may or may not impact my budget largely.
 
what you're doing is very similar to mine. i went with a trail-tech fabrication adapter for my 4l80e/241c. if you're willing do some welding this allows you to clock your transfer case to get more ground clearance.
http://www.pirate4x4.com/forum/moto...ts-replaces-stock-full-spline-engagement.html

as for A/C, i went with a kit from Summit. this kit and a spacer kit to mate it up to the cylinder head get the compressor and tensioner mounted up. the kit tells you a few belt part numbers that will work depending on your engine.

kit:
http://www.summitracing.com/parts/sum-csumls101

spacer:
http://www.summitracing.com/parts/hly-21-3
 
87burbman said:
Hey everyone. My 700R4 is basically dead, i've been doing a ton of research trying to prepare for the swap and had a couple of questions on a few items I'll need. I'm picking up a whole 2002 1500 4x4 on Saturday so anything from the donor I will need I will have. I plan on doing the whole swap for under 2k (hopefully well under) after parting out the rest of the truck and selling my drivetrain as it is. The 350 is running like crap as well so why spend the money when this option is out there! I am not used to these trucks by any means. I also have a built 84 Long bed on 1 tons and 42s and an 85 K20 plow / landscape rig. I NEEDED the burban for a growing family. I know I know, great excuse.

Here is what I know

1. 2002 5.3 DBC

2. Matching 4l60E

3. 1990 NP241C transfer case and gauge cluster for VSS

4. AC Delco EP381 which will fit into my current tank setup. Wix 33737 filter. I still have to pinpoint all of the fitting and lines I will need to use

5. Wiring harness and PCM will be sent out unless someone can convince me to do it myself. Not sure I have the time as I will be taking time off from work just to do the swap

Things I don't know.....

6. What motor mounts will I need with this engine/tranny/tcase setup in order to maintain my current driveshafts? Through my research the setup i'm going with should all bolt together directly and theoretically in the stock locations....depending on the mounts I use. I know dirty dingo is adjustable but notching of the front cross member is needed. Any way to avoid doing that with another set of mounts? I see a significant number more 2WD swaps than 4wd which don't have this issue.

7. What manifolds / headers will work with the above motor mounts?

8. I will be using this AC setup unless the compressor is too small for a suburban with rear AC. Does the size of the compressor matter? If I need a bigger compressor I will have to dish out for one of the more expensive solutions. http://www.maliburacing.com/forum/viewtopic.php?=34&t=79059

9. I will be reusing my stock radiator unless it is better to use the one that comes with the 5.3. I see most people reusing their current but most people don't end up having the donor truck. Should I be purchasing an electric fan setup or can I maintain the stock?

Thanks for any help in advance. I've read through a ton of threads front to back but have been having trouble tracking down this exact setup and answers. It seems noone is running my exact setup that I can track down and has actually finished updating the thread. And unfortunately I don't have the fabrication skills I wish I had :dunno: aka zero.

On a side note, i purchased my burban in Addison / Jackson Mighigan. My searchtempest addiction got the best of me and next thing you now my brother and I are on a flight from Boston to Detroit. Anyone from that area recognize the truck?:D

263dahj.jpg
263dahj.jpg
Click to expand...


3. NP241 and 4L60E is a bolt up affair.

5. The harness is easy. LT1swap.com has all you need to know. Save the money on having it done.

6. Dirty Dingo mounts will keep your driveshaft and crossmember placement factory. Use DIY4X poly motor mounts (lower only) to clear your factory crossmember, no notching.

7.Factory Trailblazer SS manifolds bolt up with absolutely no clearance issues.

8. I used Kwik Performance bracket and Sanden 508.

9.Factory radiator and windstar fans here.
 
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