Darn I was hoping you had an 8.1L tree in the backyard. 
CK5
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1989 Crew Cab Tow Rig Build
- Thread starter Kay86K5
- Start date
Darn I was hoping you had an 8.1L tree in the backyard.
That would be one big a$$ tree
Got some more things done this weekend. Finished filling up all the fluids in the truck including t-case and power steering...so all fluids are done for start up.
I also fixed my knock sensor issue. If you are going to run older big block headers on an 8.1, you will have clearance issues with the driver side knock sensor (found this out after I installed the headers...the knock sensor doesn't touch the headers, but there is no way to get a plug on it). So I used part#: 213-298 which is designed to go in a different location on the block (pretty much right next to the old location...you can look at the picture above to see the difference). So here is a pic of the new knock sensor in the new location
And this one if for @skunked since I know he pointed this out a while ago....I also put these little sleeves over 6 of the 8 spark plug wires as most know, when putting headers on an LS style engine, you have some issues with the boots touching the headers. I didn't want to spend the money on new ceramic booted wires right now, so just purchased these to do for now until I get nicer wires (and I only did 6 cause there were one wire on each side that were not touching the headers at all, so didn't bother with those since this is somewhat temporary)
And I also finished off my clutch system. First off I purchased this little tube adapter thanks to a link from @Russell :
https://www.swagelok.com/en/catalog/Product/Detail?part=SS-500-6-4&item=
So I installed the 95 NV4500 external slave cylinder and ran the 95 hydro line up to the 87 master cylinder that was bolted to the firewall already. I then took the hard line that comes out of the 87 master cylinder and bolted it up. I cut the two lines at a desired point I wanted the tube adapter to be at, and boom, this is what I had. I then filled the clutch system up with fluid and bleed the clutch...and there are no leaks and the pedal feels really good
So anyone else putting a external slave NV4500 into a square body....there ya go (thought it might be worth putting some pics of this cause this was one of the hardest things to find info on...so hopefully it helps someone else)
So, as of right now, it should just be wiring harness and that's it. Going to be out of town this weekend for the 4th, but next weekend going to see if we can get that knocked out and see if it runs!!
I also fixed my knock sensor issue. If you are going to run older big block headers on an 8.1, you will have clearance issues with the driver side knock sensor (found this out after I installed the headers...the knock sensor doesn't touch the headers, but there is no way to get a plug on it). So I used part#: 213-298 which is designed to go in a different location on the block (pretty much right next to the old location...you can look at the picture above to see the difference). So here is a pic of the new knock sensor in the new location
And this one if for @skunked since I know he pointed this out a while ago....I also put these little sleeves over 6 of the 8 spark plug wires as most know, when putting headers on an LS style engine, you have some issues with the boots touching the headers. I didn't want to spend the money on new ceramic booted wires right now, so just purchased these to do for now until I get nicer wires (and I only did 6 cause there were one wire on each side that were not touching the headers at all, so didn't bother with those since this is somewhat temporary)
And I also finished off my clutch system. First off I purchased this little tube adapter thanks to a link from @Russell :
https://www.swagelok.com/en/catalog/Product/Detail?part=SS-500-6-4&item=
So I installed the 95 NV4500 external slave cylinder and ran the 95 hydro line up to the 87 master cylinder that was bolted to the firewall already. I then took the hard line that comes out of the 87 master cylinder and bolted it up. I cut the two lines at a desired point I wanted the tube adapter to be at, and boom, this is what I had. I then filled the clutch system up with fluid and bleed the clutch...and there are no leaks and the pedal feels really good
So anyone else putting a external slave NV4500 into a square body....there ya go (thought it might be worth putting some pics of this cause this was one of the hardest things to find info on...so hopefully it helps someone else)
So, as of right now, it should just be wiring harness and that's it. Going to be out of town this weekend for the 4th, but next weekend going to see if we can get that knocked out and see if it runs!!
Soooo close.
Looks good
Looks good
Haha that's how I did my slave cylinder on my 77.
EDIT: and yes it works fine
EDIT: and yes it works fine
Last edited:
Glad I could help! I found that the clutch was perfect with the 85+ MC and the NV4500 slave. It works well with internal slave cylinders as well BTW.
Good info. And thanks again! I was actually surprised how easy it was to adapt the two with that tube adapter. After bleeding it the pedal feels pretty good. Can't wait to fire this thing up and actually feel the clutch while driving!!
Nice progress. You make us all proud!
Despite being stupid expensive, Swagelok makes some very impressive fittings.
We use them on 3000 PSI process impulse lines with zero leakage at work. They will hold over 22,000PSI before the 0.83 wall 1/2" tubing they are connected to bursts without any leakage whatsoever. The tube never bursts beside the fitting either because of the way the ferrules hold onto the tubing and seal against it. They are easy as a simple compression fitting to install, but don't change the ID of the tube or creating stress points.
Small little update on this thing....I worked on getting the wiring harness roughed into the truck this last weekend with a buddy. We got everything hooked up and spliced the couple wires we needed to (this stand alone harness is worth it's weight in gold), and got it to the point where we could crank the motor over. I found out very quickly that my actual fuel sending unit was bad and it was squirting fuel all over the place. It wasn't my flare/fittings leaking at all, it was the actual sender itself. So I went and got a new one, re-flared the lines and hooked everything back up. By that time it was really late and I got to the point where it was still cranking but no fire. I put a code reader on it and it said my throttle position sensor was bad (which I figured as it was a little damaged on my mech throttle body when I purchased the motor). So I just picked up a new one of those and will put it on this weekend.
I'm thinking I don't have spark and am not getting power to the coils. So I plan to double check that fuel pressure is ~58 psi like it should be (I didn't have my gauge with me and just checked I had fuel at the rail last week which I did), and double check that I have spark, and that I all my sensors are plugged in all this weekend. Hopefully I can take a short video of this thing running...we will see. If all else fails, I have a buddy with EFI live that said he will come over and plug it in to see if we can figure out why it won't fire if everything else above is in line. We shall see.
Anywho, that's what I got this weekend. Sorry no pics, but figured people wanted to know the status of this thing.
I'm thinking I don't have spark and am not getting power to the coils. So I plan to double check that fuel pressure is ~58 psi like it should be (I didn't have my gauge with me and just checked I had fuel at the rail last week which I did), and double check that I have spark, and that I all my sensors are plugged in all this weekend. Hopefully I can take a short video of this thing running...we will see. If all else fails, I have a buddy with EFI live that said he will come over and plug it in to see if we can figure out why it won't fire if everything else above is in line. We shall see.
Anywho, that's what I got this weekend. Sorry no pics, but figured people wanted to know the status of this thing.
I hope you get it ironed out quick.
Man, so close. Can't wait to see this thing hooked up to a trailer!
I'll get it figured out. I'm going to work on it all day Saturday. I'm hoping I can at least figure out where the problem is and either fix it this weekend or get the parts to fix it. Either way, it's cranking and that's a good sign. And the fuel problem was obvious and a relatively easy fix. That's why I think it's gotta be spark and maybe the coils are just not getting power or maybe the grounds to them are not good. So I will double check everything.
Getting closer. I still have a few more things, but it's getting pretty darn close
Oh, and also on a side note, I did order up and it has already showed up, my lift kit for this thing. I really want this truck to be nice and ride pretty nice down the road. So I decided to work with ORD and I ordered up there 3" lift kit. 3" HD springs in the front with sway bar disconnects, new u-bolts, steering correction ect., and a shackle flip in the rear with their HD shackles. I also splurged a little bit and got Bilstein 5125's. I figured that might help get the ride quality out of this truck I'm looking for since I plan to use it for towing on longer trips too. Sorry, didn't get any pics of it, but all the parts are in boxes right now. I plan to first get it running so it can move under it's own power, then install the lift (probably over a couple weekends), then get exhaust done. THEN it will be ready to get registered and be driving on the road. So still a bit more work....but getting closer and closer
Again, we are pretty close to the same suspension.
Gonna be awesome this weekend when you get it fired up!
Those harnesses are grounded right? Another thing to double check.....
Great minds think alike
That is the plan...but sometimes my plans go to s**t, haha
Yes, the harness had 1 ground wire to hook up. I'm almost positive that one is all good, but will double check. I read that there are grounds for the coil packs harness that are on the back of the motor (if anyone else can confirm this). I'm going to double check those if I'm not getting spark to see if that is the problem. I think there are only those and maybe one or two other chassis grounds on these things, so I will double check all those too. I'm sure I'm just missing something small (hopefully)
