1987 K30 Project

[Mr. 250r]

Well.. i did it again got another vehicle because i just couldn't pass the deal up yet im slowly getting over regretting buying it lol but anyways here it is

1987 K30 Dually - TBI 454/SM465/NP205/D60/D70



As you see it came with regular tires and from the original pictures i got, it looked like a srw setup but when i got there i noticed it wasn't. I kind of wanted a dually mud truck anyways but who knows what ill do



I put my suburbans 38s on it to see how it sat and the width and the height of the truck since it is claimed to have a 12in lift which i will likely get rid of for something smaller



Here you can tell its sitting a little wide.... no inner fender rubbing though lol



I find this to be somewhat rare a radio that's not all hacked up and cut out for another radio



A picture underneath the driver side which looks the same as the passenger no rust issues, only actual rust issues i found the the rockers/cab corners/inside lower doors have some holes yet the floor pans seem solid but ill check further into all of it later



Now for some of the bad stuff... here is the bottom of the new strainer



The topside of the strainer



And the inside of the gas tank... not looking too good although the tank itself is fine the inside is not i will probably be getting two new ones instead of having them cleaned etc because the price will end up being more expensive



The truck was scheduled to have hydraulic steering and rockwells. It ended up sitting forever then i got it and cut this stuff off i could've broke it off by hand since the welds are extremely poor but i just torched the plate off instead



This is a great example of what i cannot stand. Welding stuff just because you can. This is a hitch welded to the inner frame rails the welds although better than the steering stuff they are still not acceptable to me. This is annoying because its gonna take some decent grinding work to fix it all up, I've already cut it off but haven't started grinding yet


Unfortunately my biggest problems are the fuel and steering related hopefully it or the suburban will be done before may 4th for the mud bog

[Rusty Shacleford]

I've always wanted to do one of these, but all of them I find are too high ($$$) for me to justify or full of rust. I'll be watching this one.

[johnnyclack]

Man cleaning up those welds on those inner frame rails is goging to be a tuff row to hoe.

Better you than me,

Be sure to keep your heat to a minimum, with that much weld the frame steel may already be compromised

[Mr. 250r]

Originally Posted by Rusty Shacleford

I've always wanted to do one of these, but all of them I find are too high ($$$) for me to justify or full of rust. I'll be watching this one.

I know what you mean and had this had a carb on it instead of the original tbi i would've never even of got it but i saw that and i thought to myself this is rare someone that left it on.... might as well see how bad the rest looks lol and its not looking the best

Originally Posted by johnnyclack

Man cleaning up those welds on those inner frame rails is goging to be a tuff row to hoe.

Better you than me,

Be sure to keep your heat to a minimum, with that much weld the frame steel may already be compromised

Yeah its not gonna be easy fitting a grinder in there and getting it right as some people might just kind of get off the old stuff im looking to do it right and make it look like it was never there which will take much more effort but i don't mind, and as far as the heat i see what your saying as its not the thickest metal but i don't believe there was enough weld and heat to affect it. The front is the part that had me worried since it looks to be a sad attempt at a vertical up and a thicker/wider weld on a more important area but the weld was so poor i nearly broke it off by hand so i wouldn't consider that being any issue.

Some news on it i got a tank, sending unit, fuel pump, filter ordered. I haven't checked the driver side tank but i believe its going to be worse sense the sending unit is just moving about freely in it so ill just run one for now. I will also be getting injectors since when it was run before i bought it one was clogged or something most likely from all the stuff in the tank and lines so i figure why risk it? Just buy new

Next week is when i will be either really happy or really angry, stay tuned. *Also notice the front brake lines have a broken stick or something in them... some people.*

[Mr. 250r]

Small update here. I called a friend over to help me drop the other tank and look at some other stuff and here's what i found.



Here we can see that instead of just unclipping the driver side sending unit someone found it easier to take more time to cut them... right above the plug..



I sure found out the driver side was worse



If rust in the tank equals horsepower i might have something here



And the rear end... only took about 30+ minutes to get off it was like super glued on and since the breather hole wasn't plugged our friendly rain decided to drop in and party



Rust pitting the....4.10s

Last but not least we notice the steering box holes are wallowed out mainly just the bottom left one



Also found one bad rust spot in a weird spot under the cab on the drivers side on top of the frame and some more wiring issues but nothing i haven't anticipated as that's part of the cheap truck/mud truck fun

[Mr. 250r]

Haven't done a whole lot as i was waiting for parts to arrive which finally have an include a gas tank, sending unit, fuel pump, fuel filter, injectors, tbi gasket kit, undercoating and undercoating gun

Here is some pics to show what has happened since the last post

Here is a clean tbi setup



Another clean tbi shot



Here is the D60 all 80s gore like



Another



A problem with tall springs is they rub the frame although its hard to tell and getting lower shackles makes my already bad pinion angle worse and it already has shims, so i am debating an 8in spring in the front but haven't fully decided



A spring reference shot



Ill be under coating the gas tank probably tomorrow... i was going to have it done by a bed place but it was quoted at a ridiculous 125+ so i'm doing it like we do under our truck beds at work 3M undercoating with an air gun. I also possibly mess with the fuel related stuff since the 3M stuff dries really fast

[johnnyclack]

I like it

[Mr. 250r]

Originally Posted by johnnyclack

I like it

Im 50/50 on it some days i like it most days i dont

Now here is a decent update which like anything i post will be picture heavy lol but it involves my gas tank and a pretty much complete 205 breakdown and eventual rebuild, enjoy.

Now I've personally never taken a transfer case out or messed with one so like usual i went to the internet learned what i thought i would need and then had to get my hands dirty and in the end i can say..... this was one of the easiest things i have ever done. Although i might of had some help since all the bolts were already loose on the transfer case.

Tools required *Not a complete list*
Flat head screwdriver
Rubber mallet
Snap ring pliers
1-5/16" socket
Assortment of wrenches
Assortment of punches
Patience

This is the guide i used to help me take it apart - http://www.wideopen4x4.com/NP205RebuildGuide.html, I suggest using it because its a huge help and i tried copying it as much as i could. Alsoyou can refer to this guide from ORD to help you figure out what 205 you have http://www.offroaddesign.com/catalog/NP205tech.htm, my case is a round pattern 32 long spline case

I'm going to assume everyone can get it to a work bench so that is where im starting from.

Step 1 - Drain oil and inspect if worried *I didn't drain mine before pulling*

Step 2 - Clean the transfer case *Mine was perfectly clean already*

Here we can already see some damage. Left shift rail ends bent and right shift rail has a piece of metal welded to it.


Step 3 - This much front output shaft play is all good right....?



Step 4 - Remove the lock nut from the front output shaft, i used an impact since i did not have a flange holding tool.

Here we can see damaged threads on the shaft i just buzzed through them which probably wasn't the smartest but its done now and the threads may pose a problem for me later i haven't decided.


Step 5 - Slide off yoke and remove 4 bolts for the seal/bearing retainer housing

A small screwdriver or pic may be required to pry it off


Step 6 - Remove bolts from large bearing retainer on the back of the case then remove the cover.


Step 7 - Tap the front output shaft with a rubber mallet out of the case


Step 8 - Remove the snap ring then bearing


I will continue posting more on this tomorrow

[johnnyclack]

Great Pic's; Keep up the good work

I wished I had that bench top in my garage

[Mr. 250r]

Originally Posted by johnnyclack

Great Pic's; Keep up the good work

I wished I had that bench top in my garage

Not my garage its my dads shop lol

Anywhos on the update side of things i was going to do some stuff sunday as we can see that didn't happen i ended up being busy and tonight i did some stuff and tomorrow i will do some more so expect pictures by the end of the week as i may get it to mud fest... but i doubt it

[obijuan]

If it were me id lose that stock front 30 spline output shaft and put in a 32 spline one. Stronger and fits any yoke. You're not stuck with stock cv.
I see a 400/203 adapter. Going doubler? Ive got a couple 32 spline front outputs and an ord doubler figure 8 adapter im looking at letting go. This truck could certainly use one.
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[Mr. 250r]

Don't plan on swapping in the 32 spline im just looking to get it up and running so i can actually make maybe 1 mud fest this year but its looking grim lol and as far as the doubler... nope. Not a fan of doublers, 205s or big blocks =-p I just happened to get stuck with 2 of those but i do like ords magnum box taking place of the adapter but all that stuff costs money and i just want to go mudding already. Now if the front output breaks then ill probably go to the 32 spline but whats funny is the former owner said he broke the front output but after i took it apart i found it had already been taken apart and they must've forgot a spacer which was giving the output so much play but he did break the S connector on the rails but i have one already so i should be good

[Mr. 250r]

Well some good news and bad news.... the good is i went to the junkyard and got a bunch of square body stuff the bad news is im spending a lot of money on a truck that still isn't off the trailer lol but in other news i had some fuel pump wiring issues the guy wiring my 6.0 swap in the suburban fixed it temporarily and will end up making me a harness for a single tank setup for now but after the throttle body rebuild, oil change, wiring fix. The truck.... started up after a second crank and runs smooth as can be and hooked up the scanner since no check engine light is hooked up and no codes so.... good news mainly.

I got a crossover setup coming ORD setup with NWF arm still haven't got the box but its getting near and i will finish the 205 build i had some idler gear shimming issues

[thirdstreettito]

Subbed!

[Mr. 250r]

Haven't got much done got annoyed with ORD's D60 stud kit both studs ending up bending on me and i went with a crossover but that's being problematic getting it all sorted out, still haven't messed with the 205 because no one has idler shims i asked ORD and they said they don't come in kits anymore and don't know where to get them so im having my friend machine me 4 new ones but in other news i got some parts from the junk yard and craigslist

A low mileage gauge set from a suburban


Dual headlight front clip swap and interior pieces from suburban


some other stuff like a rear cab light from junk yard and... an oil cooler and i will be getting a rear sway bar if its still there soon

[Hoods69BadBowTie]

Looks like a fun and time consuming build like they all are. I have always wanted to do a Crew Cab big mud truck myself! Still got the beast any progress of more pics on the build?

[Mr. 250r]

Well good news and bad news the bad news is i still have the truck lol the good news is its getting closer to moving, i got the 205 shims from quad4x4 and my uncle ended up installing them while i was at work. Also i had the electric fan tested and it works then my fuel pump locked up because the tank was too low and it sat to long so i got another pump put it in, took a little bit to fire and now there's magically a strange motor noise which is just what i needed and last but not least i had the steering block milled a 1/4in and put the nwf arm on and finally got my psc rebuilt 2wd box installed by myself which was a job by itself so.... that's where im at i was gonna work on it this weekend but im on overtime and got called in for saturday so i probably won't touch it
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[Hoods69BadBowTie]

The bad news is you still got it nice haha! Wow sounds like its one of the 2 steps forward 1 step backwards project. That sucks about the fuel pump and motor noise. That's weird it didn't make it at first. Hopefully its nothing that major. I been there before with wanting to work on the truck and always working.

[Mr. 250r]

Back on the project this weekend with some good news. Second fuel pump went out lol so i got a delphi this time as they didn't list ac delco so hopefully this one holds up even though there was a strange rattling noise in it.... but now it starts and runs fine and i put some oil in it and the odd growling noise has mysteriously disappeared im not sure if it was because of the oil or what but its gone for now and im happy. My brother helped me put the 205 back together then i loosely put the steering stuff back together nothing tightened down had a friend steer it while i pulled it in the shop and 2 of my friends helped me put the t case back in the truck which was a little job on its own. Now i need 3 pto cover bolts and oil for the case, power steering fluid, 2 u joints and hopefully it will then move under its own power if not im gonna scrap it and go back to the suburban

[Mr. 250r]

Kind of forgot about this build since i have 2 others and man i got bored of all 3 so i took a break for awhile but i am back and messing with the suburban and maybe this but the 89 will have to sit for a bit. As far as this goes... the battery i bought and dropped has a crank on the top so its junk, haven't started it in forever so the fuel pump probably went out and i am pretty sure i lost the key to the steering column. The front output seal in it was wrong but i have a new dual lip seal i haven't put in so that's about where i stand besides i put a new u-joint drive shaft by the axle and that squeaks but its better than having no bearings i guess. No updates for awhile unfortunately.