y5mgisi
1 ton status
That is terrifying. Looks like i could handle it though!
CK5
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Project Penny - All good things must come to an end
- Thread starter Russell
- Start date
Russ do the tahoes lines run down the drivers or passenger side? I know the lines are factory on drivers side in the dmax. If they are passenger are you just going to cross over the engine?
Cool, are you using the factory dmax engine side mounts and making custom frame mounts, or how is it going to work. Nice progress man, I bet you will feel glad when it's all bolted in and in place, that will be a big milestone.
The lines are on the driver's side as well. I'll be using the existing supply line as the return line and will be fitting a new 1/2" supply line to replace the old 5/16 return line.
I will be making new engine side mounts to fit the existing frame mounts. The stock Duramax mounts are very different.
I will be making new engine side mounts to fit the existing frame mounts. The stock Duramax mounts are very different.
swedester
1/2 ton status
nice progress!and very interesting to actually see how much work it is to do such a swap,I wouldn´t mind a d-max in my old burb,I´m taking notes...
supersize75k5
OrganDonorRacing.com
Russel you missed our movie date last night
But this thread makes up for it
But this thread makes up for it
Sorry man! By the time my flight would have landed and I made it to the theater, it'd have been a little be past when the movie was done :P
Maybe give me more than an hour's heads up next time?
Not much progress tonight unfortunately. I cut the shifter hole out with my plasma cutter (I love that thing!) and got the shifter boot installed. Took me most of the night cause I had to take the seats out and it took a long time to lift the carpet / all the PO's sound deadening material (which was siliconed down and was made out of glass insulation with foil backing, doh!)
Tomorrow I'll be steam cleaning the carpet to try and clean it up a bit and will be re-installing the seats / center console. If I have time, I will also tear down the NP241 / NP261 so I can swap input shafts to convert my 241 into a 29 spline transfer case.
Wednesday I'll finish the transfer cases up and bolt the 241 up to the ZF6. Hopefully by Thursday I'll have my engine mount plans so I can get them made up and the engine installed. Then it goes over to Andrew's place so he can make a new engine crossmember and brace up the front end a bit better. Then the engine comes out for a final clean up and the frame will get painted. Hopefully be able to drop the engine and transmission in permenantly by the end of Sunday night. That will allow me to hook up my drive shafts then start running my new fuel lines. I'll need to drain the fuel tank and drop it out so I can modify the fuel pickup. Not really looking forward to that particular job
Oh, btw, big brown truck stopped by today, robbed me of another 120 bucks brokerage fees and dropped off some goodies from PSC
Hurray for hydro assist!
Anyways, couple pictures for you guys... 2.5 weeks left to get this thing running before the car show, kinda worried I won't be making it...
Maybe give me more than an hour's heads up next time?
Not much progress tonight unfortunately. I cut the shifter hole out with my plasma cutter (I love that thing!) and got the shifter boot installed. Took me most of the night cause I had to take the seats out and it took a long time to lift the carpet / all the PO's sound deadening material (which was siliconed down and was made out of glass insulation with foil backing, doh!)
Tomorrow I'll be steam cleaning the carpet to try and clean it up a bit and will be re-installing the seats / center console. If I have time, I will also tear down the NP241 / NP261 so I can swap input shafts to convert my 241 into a 29 spline transfer case.
Wednesday I'll finish the transfer cases up and bolt the 241 up to the ZF6. Hopefully by Thursday I'll have my engine mount plans so I can get them made up and the engine installed. Then it goes over to Andrew's place so he can make a new engine crossmember and brace up the front end a bit better. Then the engine comes out for a final clean up and the frame will get painted. Hopefully be able to drop the engine and transmission in permenantly by the end of Sunday night. That will allow me to hook up my drive shafts then start running my new fuel lines. I'll need to drain the fuel tank and drop it out so I can modify the fuel pickup. Not really looking forward to that particular job
Oh, btw, big brown truck stopped by today, robbed me of another 120 bucks brokerage fees and dropped off some goodies from PSC
Hurray for hydro assist!Anyways, couple pictures for you guys... 2.5 weeks left to get this thing running before the car show, kinda worried I won't be making it...
wahlstrom1
Registered Member
Slowly gettin there.... Seeing it in person, the engine definitely fits the 88-98 bodystyle better then the 99+. It was a pain to do the injectors when the engine was in the 02', but they are much more open now, flat firewall instead of a hole to tuck the engine into....
That's because the duramax was designed and tested in the 88-98 body style trucks. That's also why there is that little notch cast into the drivers side exhaust manifold on the early duramaxs, to clear the steering shaft of the old chassis.
Very cool project
. Wish I had the time and money to do something like this.
Very cool project
. Wish I had the time and money to do something like this.
Well, some more progress again tonight!
Headed out that way and got to work on my transfer case. I had to tear it down and swap the input shaft from 32 spline to the 29 spline from the NP261 so I can keep my SYE and driveline park brake. Fortunately, it is a direct bolt in swap Unfortunately, not so much for putting the 32 spline input into the 261... The input shaft will need some machining to fit properly in the newer t-case for Andrew's Cummins swap.
Regardless, I have the t-case re-assembled and ready to go back into the truck. I didn't take any pictures, however, as my hands were covered in ATF and I didn't want to be playing with my phone and getting it covered in ATF too.
I also drained out most of the fuel from the fuel tank so I can drop it out of the truck tomorrow, and was happy to recieve not only a parcel notice from the post office for all my D60 outers (woohoo!! thanks ORD!) but also my 800 core refund on the Duramax injectors.
Yesterday I purchased a new steering box for the truck as well, but ran into some trouble with it. Winds up the box I bought is not a saginaw box. I am sure it works fine and well, but I haven't a friggin clue where to drill and tap it for hydro assist... I may need to return it and try to find a proper saginaw IFS box somewhere in the city...
Headed out that way and got to work on my transfer case. I had to tear it down and swap the input shaft from 32 spline to the 29 spline from the NP261 so I can keep my SYE and driveline park brake. Fortunately, it is a direct bolt in swap
Unfortunately, not so much for putting the 32 spline input into the 261... The input shaft will need some machining to fit properly in the newer t-case for Andrew's Cummins swap.Regardless, I have the t-case re-assembled and ready to go back into the truck. I didn't take any pictures, however, as my hands were covered in ATF and I didn't want to be playing with my phone and getting it covered in ATF too.
I also drained out most of the fuel from the fuel tank so I can drop it out of the truck tomorrow, and was happy to recieve not only a parcel notice from the post office for all my D60 outers (woohoo!! thanks ORD!) but also my 800 core refund on the Duramax injectors.
Yesterday I purchased a new steering box for the truck as well, but ran into some trouble with it. Winds up the box I bought is not a saginaw box. I am sure it works fine and well, but I haven't a friggin clue where to drill and tap it for hydro assist... I may need to return it and try to find a proper saginaw IFS box somewhere in the city...
So, last night I spent the whole night working on re-assembling the D60. I wasn't sure if these solid axle industries knuckles / brakes required D60 rotors or 10 bolt rotors, and I also needed to pick up some 10 bolt calipers + pads. Found out that the rotors do indeed need to come from a 10 bolt (duhhh, 10 bolt calipers don't even fit over the D60 rotors, lol).
So, swung by Napa, dropped 450 bucks on brake parts and re-assembled most of my diff tonight I lost my hub socket somewhere, so I gotta swing by and pick a new one up tomorrow then I can tighten my wheel bearings up and put my tires back on. I put a junk tie rod on the front so that the truck can be rolled up onto the trailer and taken over to Andrew's place. There we are going to assemble the engine mounts he cut out for me and will get the Duramax + ZF6 + NP241 assembled and installed. We'll also be building the new engine crossmember and bracing up the front end a bit better while we are at it. We'll then pull the drivetrain one more time for a final clean up and paint job before reassembling it all for the final time. That should pretty much leave me with getting my steering box re-assembled, a new proper hi-steer tie rod made up, 1/2" fuel line run and of course my electrical. I've got just under 2 weeks to get the truck finished up, and I'm going to be giving up a whole long weekend to go visit Sean in Honolulu to boot! (I think it is worth the lost wrenching time :P)
Gonna be tough to finish it all, but I am fairly sure I'll get it pulled off. At the very worst, I'll be working on the wiring while I am at the car show, LOL
Anyways, couple pictures of D60 beef for you guys!
So, swung by Napa, dropped 450 bucks on brake parts and re-assembled most of my diff tonight
I lost my hub socket somewhere, so I gotta swing by and pick a new one up tomorrow then I can tighten my wheel bearings up and put my tires back on. I put a junk tie rod on the front so that the truck can be rolled up onto the trailer and taken over to Andrew's place. There we are going to assemble the engine mounts he cut out for me and will get the Duramax + ZF6 + NP241 assembled and installed. We'll also be building the new engine crossmember and bracing up the front end a bit better while we are at it. We'll then pull the drivetrain one more time for a final clean up and paint job before reassembling it all for the final time. That should pretty much leave me with getting my steering box re-assembled, a new proper hi-steer tie rod made up, 1/2" fuel line run and of course my electrical. I've got just under 2 weeks to get the truck finished up, and I'm going to be giving up a whole long weekend to go visit Sean in Honolulu to boot! (I think it is worth the lost wrenching time :P) Gonna be tough to finish it all, but I am fairly sure I'll get it pulled off. At the very worst, I'll be working on the wiring while I am at the car show, LOL
Anyways, couple pictures of D60 beef for you guys!
This whole thread is insane! 
That looks pretty trick! You are getting it done quick, can't wait to see how you mount the engine in there.
I think I need a career change...duramax swaps, awesome trips!
Good for you Russ!
Good for you Russ!
All kinds of progress today! Started off by finishing up installing the new outers on the D60. It is still missing it's inner axle shafts (new Yukon 4030 chromos ) but I wanted the truck back together so I re-assembled it without them for the time being 
I then put my tires back on and set it back down. Looks good! My camber is finally straight like it is supposed to... A straight D60 is much better than a bent up D60
Anyways, next on the agenda was to install a new steering box which I went ahead and drilled for the hydro assist. I didn't have a 1/4" NPT tap here, so I'll have to finish tapping the box tomorrow. I also installed my new temporary tie rod (it is 1.5" instead of the 1.25" I want to run...) and reinstalled my drag link.
I then got to work cleaning up my shock tabs and welded the new hydro assist mount together / tacked it on.
Unfortunately, Andrew wasn't able to make it over today with his big welder (my little 110V unit doesn't have the balls to do any important welds, haha). When he makes it over tomorrow, we should be able to get the engine mounts built and will get all the shock tabs / mounts welded to the diff, as well as bracing up the front end a bunch. With some luck, we should get the engine bolted in tomorrow
) but I wanted the truck back together so I re-assembled it without them for the time being I then put my tires back on and set it back down. Looks good! My camber is finally straight like it is supposed to... A straight D60 is much better than a bent up D60
Anyways, next on the agenda was to install a new steering box which I went ahead and drilled for the hydro assist. I didn't have a 1/4" NPT tap here, so I'll have to finish tapping the box tomorrow. I also installed my new temporary tie rod (it is 1.5" instead of the 1.25" I want to run...) and reinstalled my drag link.
I then got to work cleaning up my shock tabs and welded the new hydro assist mount together / tacked it on.
Unfortunately, Andrew wasn't able to make it over today with his big welder (my little 110V unit doesn't have the balls to do any important welds, haha). When he makes it over tomorrow, we should be able to get the engine mounts built and will get all the shock tabs / mounts welded to the diff, as well as bracing up the front end a bunch. With some luck, we should get the engine bolted in tomorrow
wahlstrom1
Registered Member
And here you thought I was slacking on my own stuff, lol.... I need a 48hr day! Reminding ya here before I forget.... York Bracket?
On it's way!
Before you paint those shafts make sure they fit through the knuckle, mine had to be ground on a little to fit through the knuckle. Nice progress again!
Oh... I should mention, this thing has been running and driving with the dmax in it for a while now :P Actually about to haul it down to Las Vegas to run as a chase truck for 4502 (Ultra4 based out of Edmonton, AB that we ran at KOH this last winter) in the Vegas to Reno run. I'll then be running the Rubicon Trail before coming back home.
And yes -- A 2-dr Tahoe with a LB7 / ZF6 is lots of fun
And yes -- A 2-dr Tahoe with a LB7 / ZF6 is lots of fun
