72 K5 Blazer engine/trans swap 5.3/4L60

[Gunny Davis]

New Member over due upgrade.

I have had my prize Blazer nearly 10 years w over 70K on the rebuld and it is starting to show the wear. This is my daily driver so I am hoping to improve the power and MPG and not have it down too long.

I picked up a salvage 99 Silverado and plan on stripping everything I can...
5.3 Vortec, 4L60e Trans, harness, computer, fuel system, seats, insturment cluster, and what ever else I can get my hands on.

Started on the Blazer today. Both engine and trans original needs some attention and showing signs of wear so I thought this would be a good time to get going on this project I have wanted to do for quite a while.


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[Thealien]

good luck, love mine

[Gunny Davis]

Got back to work on the Blazer today.

Engine is ready to come out once I figure out how to get the Trans/Tansfer Case loose. Anyone done this I could use some advise.
I have droped the t/c skid plate just not sure where to start with the Trans. I want to pull the Engine tranny as one piece.

I also droped the fuel tank. Need to get busy on the Fuel system set up. I want to take the sending unit and pump from the 99 silverado donor I have and modify it for the Blazer tank.
If any one has done this I would appreciate the help; or advise on where I can get this done.

[Clyde65]

I agree with thealien, love my LS too. I dont have any insight for you, sorry man.

If you need some advise locally, give Clienbarger a holler, he is in Ft Worth off Belknap st.

[Gunny Davis]

Brand new here.. Who is Clinebarger? Is he a tansmission guy?
I'm a Fireman in Fort Worth and work off Meadowbrook. I could def use an honest contact if he is just over on Belknap

[Gunny Davis]

So, spent like 2 hours today just trying to get the bolts out of the 4bolt trans-to-transfer case adapter... who knew. There has got to be an easier way. I was under the truck contorted in all kinds of positions with grease to my elbows trying to get at the last bolt (top Passenger side) I have got to get the engine and trans out next day so I can get it on the market and get to work on the 5.3 install.

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Also; want to convert the fuel tank by modifing it to take the sending unit and pump from the donor 99 silverado. figure I can cut larger hole and work it from there. Anybody done this? I think I can save a fair amount of money with this mod

[Clyde65]

Gunny, here is his profile. Ill look for his ph # and send it to you in a PM, in the mean time, PM him, he is usually on here daily.

http://67-72chevytrucks.com/vboard/member.php?u=57654

[Clyde65]

I sent him a PM for you

[Gunny Davis]

Thanks god for hillbillies! had my buddy come help me with the hood. After I told him how much trouble I was having with the one bolt; he looked at my truck and was like... "why don't you just go at it from the top. No ****! So I waited for him to leave and removed the boot from the 4WD stick. BAM! right there.

Got a couple of rusted out holes in my fuel tank sooooo.
Think I found a 99 Tahoe tank on line that I can fit the sending unit/pump from the doner pickup right into. If it will fit I can save quite a bit of $$$$

[Gunny Davis]

So I am having trouble figuring out the motor mount thing.
I am swaping a 99 5.3/4l60e; I added the Advanced Adapters 6-4 bolt kit to mate up with my NP205 T/C. It looks like it added about 1-1.5 inches to the trans length. If I want to keep the T/C in the stock location which motor mounts do I need?
Looking at trans chart my original TH-350 (21 5/8 long), 4L60e (21 3/4) but My measurment today looked closer to 24inches. So stinking confused

[Thealien]

Pacific fabrication is the only 4X4 crossmember/motor mount option available unless you build custom like I did. You may have to relocate some brake lines to use it. A member here firebirdjones recently used one and that was his experience.

[Gunny Davis]

[IMG]fule tank mod.jpg[/IMG]Decided to just go with the original fuel tank...
Had to patch up some small rust holes and mod tank to accept the 99 fuel pump.
Just cut 4inch hole in tank, with jig saw and metal cutting blade, and drilled 4 bolt holes for the locking ring. Fit and worked like a champ.
Cost = $0.00

[Gunny Davis]

Ok, now that i'm finaly getting close to "put it all back together" phase. I have a few questions.

1) What are the emission rules in Texas for engine upgrades?
2) What emissions can I eliminate (I have all the original pieces from the donor truck...O2 sensors, cat's, everything). What about the EGR and that pipe that runs from the Pasng manifold.
3) I'm running the fuel "Feed" and "Return" line. I understand the third line is a fuel vapor, or something like that. Can I eliminate this line?

Thanks for ya'lls help

[Clyde65]

Emissions are for the year of the truck, not the motor. you need to eliminate the rear O2's and something I cant remember. that is the thing you can eliminate. they make a blocking plate but I heard a smaller freeze plug works too.

You going to Cruise for a Cure in Downtown Ft Worth Saturday?

[usmcchevy]

[QUOTE=Clyde65;4900698]Emissions are for the year of the truck, not the motor. QUOTE]

No idea on TX laws, but going off what Clyde said you can eliminate: cats, rear O2s, EGR(if you have it) and EVAP. EVAP is the solenoid on the top front of your intake that had a tube that originally went to the charcoal canister.

[Gunny Davis]

Thanks guys for the input.
I'm going to eliminate the rear O2's the EVAP and EGR.

Next gotta get the motor mounted up and attack the wireing harness

Clyde- got duty this weekend so no cruisin, but I really need to catch more local events

[Clyde65]

Awww, I have been there, what outfit are you with? dont forget your cats!

What USMCCHEVY said is what I did on mine.

[Gunny Davis]

I am with an Engineer Detachment here in Fort Worth.

I used the Advanced Adapters 6 to 4 bolt adapter to mate the 4l60e trans to the NP205 Transfer Case... heads up the supplied bolts are allen head but there is not enough clearance between the T/C so I had to get some standard hex head bolts. Couldn't use socket either; had to go with plain ol wrench.

Now on to the wiring. I want to use the 99 insturment cluster like NiceGuy did. So I need to recover the connecter and figure the wires nesassary to allow all the guages work.

I'm also pulling the cruise controll and I plan on useing the 99 fuse block as well. Has any one done this?

[Gunny Davis]

I guess I took for granted the Advanced Adapters engineering and fit and assumed the adapter I paid $$$ for would work with out any problems. No; the instructions have a small note *** for T/C adapters from original TH350 you must have the cast shoulder machined off and remove .500 from the sleeve.
So after about three different tries I finaly realized it was not going to fit and went back to the instructions were i found the issue. Had a buddy do the machine work for me and now I finally think I have a solution I can get to work on. I did go ahead and remove the two seals and once I get those replaced I hope to get the motor in place to mock up the motor mounts.





I did have the machinist replace the chamfer on the trans side to assist with assymbly

[Gunny Davis]

I am going to have to fab up the motor mounts so I need some help with the position of the motor in the frame.
How do I find the proper height and angle for the engine before I fab motor mounts?

Motor mounts have been much more difficult then I anticipated. I read all the "easy adapter plate" advise on here only to find that my 4WD crossmember will not fit the 5.3. So stock mounts are out of the question. I have decided to go with some like the pic just need to find some 5inch c-channel for the box.
http://67-72chevytrucks.com/vboard/a...1&d=1318632365

[usmcchevy]

Would this work?

http://67-72chevytrucks.com/vboard/s...d.php?t=487797

[mcbassin]

Originally Posted by Gunny Davis

I am going to have to fab up the motor mounts so I need some help with the position of the motor in the frame.
How do I find the proper height and angle for the engine before I fab motor mounts?

Motor mounts have been much more difficult then I anticipated. I read all the "easy adapter plate" advise on here only to find that my 4WD crossmember will not fit the 5.3. So stock mounts are out of the question. I have decided to go with some like the pic just need to find some 5inch c-channel for the box.
http://67-72chevytrucks.com/vboard/a...1&d=1318632365

Gunny,
Where did you find the attached picture? Did you end up making this style mounts? If yes, Did you happen to make a sketch or drawing of what you made with dimensions? thanks

[Thealien]

Ive recomended them a few times and firebirdjones is using one.

[Gunny Davis]

You guys are absolutly right! And if I ever do this again I would go with the Pacific Fab piece. Ease of instalation would def offset the cost. Right now I am already moving along with the Mounts shown in last post pic and just need to get the engine set at the correct height.

I would love to see the pics of FirebirdJones installation but can not get his links to work

[Gunny Davis]

next big thing... Instrument cluster
I want to use the 99 donor cluster and need to figure ou the wireing. Does anyone have the pinouts for the instrument cluster connection. I have the diagrams from the Haynes manual but I am some what confused by the, 2 sets in many cases, same color wires.