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suburban 2wd to 4wd conversion

B

black dawg

1/2 ton status
Joined
Aug 25, 2011
Posts
905
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Location
montana
80 3/4 ton 4x4 all rusty and beat up

91 1/2 ton 2 wheeler very clean and rust free

I would like to put the 91 body on the 3/4 ton 4x frame.

How much work am I getting myself into. I see that the trans hump is different, and I plan on using the tbi 350 and everything that goes with it.
 
Last edited:
never body swaped a burban .

but did few trucks and few points for ya.

body mounts are frame specific not body

also if swaping tbi in if not whole motor then know your cam and and keep it efi friendly. also you will need exaust manifolds or weld in o2 sensor bung.

also tbi swap going to need fuel lines and gas tank and sender from same tank for the tbi intank pump. also going to ether add wires to pump or swap the 91 wiring over on the frame to the 80 for the tbi pump in take.

the floor hump can be cut out and grafted in place or like i did min 2" body lift cleared 465/205 and 400/205 combo's.

then other than that few little things might bump up on ya but all basics.
 
I do plan on using the tbi motor, fuel lines, and tank.

can the suburban body be lifted (using 2 post hoist) with front clip on?
 
if you plan it and lift correctly . but i would prob for safty and easy working pull front clip. and keep track of body shims and placement to pop back on perfectly.
 
ChevyBoy2010 said:
Swap axles and suspension to the 91. WAY easier than a body swap.
Click to expand...

You got me thinking now, I have enough parts to make the 91 into a 3/4 4x4 with out touching the 80. I had gotten all the brackets and spring hangers to make it 4x4 a few months ago and then found a real nice 90 1/2 ton 4x4. So the 91 two wheeler has been sitting.
 
no turning back now, got the rear end and springs out. Plan is to have 3/4 ton axles and springs in by the end of the weekend. Just a spare time deal, so we will see. Gonna get the motor pulled to make putting the 4wd crossmembers and stuff easy.

10 bolt front
c-clip 14bolt rear for now
tbi 350 th400 205
3.73

I do have access to a d60 14bff combo, but maybe that will happen later.
 
Muddytazz said:
Black dawg, swapping burb bodies is fairly easy, I've done a few.

In this link I have 3 albums of putting a 81 2wd body on a 77 frame. You are correct on the trans tunnel being different, but other than wiring its real easy.

http://community.webshots.com/user/muddytazz
Click to expand...

cool, thanks for the link.

Well trans is out and engine is out.
can I re use the 2wd steering gear?
what flexplate will I need for this 6 bolt th400 converter?

this burb has 293k on it and the engine appears original. Bearings are dated 91. Is it possible to get that many miles out of a tbi motor? It runs like new and uses NO oil.
 
next question... If I decided to use 465/205 will the pedals from the 80 work in the 91?
 
4 more holes to drill and I am ready to start bolting in the axles, suspension, and motor.
 
click edit on your orignal post you started this with. then go advanced edit. then edit title and click save.
 
It's a roller again.

Got diffs and springs bolted in.

Had to steal parts from 3 burbs to make it happen. Got the th400/205 and trans tunnel out of one burb, the front diff and springs from another, and the rear diff and springs from another.

It was a long weekend.
 
Motor mounts dont want to line up.

I used frame parts from diesel and mounts from diesel (my 80 gasser uses the same ones), are the shells on the motor different 2 to 4wd???
 
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