6.5 Swap into Gasser Sub.

[BStorm]

I have recently become the owner of a 91' GMC k2500, one could say awesome. Driving home from my new purchase, my new truck became my new project. The truck overheated and the first thing that broke was the gauge so the next was spinning a bearing. I've spent the past week replacing head gasket and doing a valve adjustment and inspecting the top end. I still have the knocking though acceleration.
I have a 6.5N.A. w/ 4L80e to put in place of the 350 /4L80e, hence my new project. The guys at the truck stop have been a ton of help. If anyone has a detailed post of the swap that would be a great help. One of things the guys that are going to help me say, "how the hell are we gonna get in there?". I have the intention on pulling the front of the clip. I wasn't trying to pull the whole front clip.
The truck has 9" of suspension, 3" of body, 4:10's, and 38"s on 20" wheels. I also have a set of steel wheels w/ 37's on 16.5's for the winter. Thanks for any help or advice I can get and I will definitely keep a detailed photo log of the swap.

 

[yellowK20]

Not to rain on your parade but the swap is pretty involved. your gonna need the Stand alone computer and harness to run the 4L80E behind the Diesel as the current 350/4L80E set up has a completely different harness.

Thats gonna be the most difficult part of the swap, but your also gonna need:

Hydro boost brake setup

Complete Accessory drives for the 6.5

all the Fuel System components

Glow plug components and associated wiring

Proper Exhaust manifolds and head pipes

Diesel radiator and shroud

Diesel Gauge Cluster

Lots of Beer


I say go for it you won't be disappointed, but its a lot of work to do it right your best bet is to find a 91 Diesel Suburban or Crew Cab Donor rig to rob parts from.

Also get on Ebay and get a FACTORY service manual AND wiring Diagram for 1991 V,R,and P series Trucks. Your Burb is a V2500 not a K2500

What year/application is your 6.5 4L80e?? becuase that can make a huge differance

 

[BStorm]

yellowK20: Thank you for the advice and the parts to be sure to have on hand. The motor trans set up is from a Milspec 6.5. All the parts list I understand except the Hydro boost. The donor motor/trans is from 99' Thank you again

 

[yellowK20]

is it a hummer engine? 99 would be an electronic engine and will ad considerable grief to the swap

 

[yellowK20]

at the top of the page there is a search button, you can type in Hydro boost, or even 6.5 swap and you will come up with TONS of info on both . Spend a few nights reading those posts there is alot of great info and different ideas you can glean from.

Questions are always welcome, That being said nearly any question you could have with these trucks has been asked before and discussed at length.


I'll try to pull up some of the links I've saved form the 6.5 swap stuff

 

[DokWatson]

If its an engine pulled out of a humvee don't forget to replace the fuel shutoff solenoid on the IP. Humvee's use a 24v solenoid with a bullet type connector.

To answer your brake question, you need hydroboost brakes with a diesel engine because they don't make vacuum like a gas engine does.

 

[BStorm]

Thanks guys. I don't ask for all the answers, I'm looking for the right things to research. I do appreciate being pointed in the right direction. I'll keep updates coming as the project evolves.