My current project

[THEFERMANATOR]

Well I guess I'm far enough into my current project that I will let you guys in on it. This is why no boats for me for the time being, this thing is taking up ALOT of my time.

Copied and pasted from another site I frequent.
------------------------------------------------------------------------------

Progress has been slow as I have too many irons in the fire, but this is where I'm at now. I have my SUBURBAN with the engine, trans, and transfer case pulled out. I also got my 01 donor's powertrain pulled out.

Here's my donor after I drove her into the shop. The radiator and intercooler were trashed from it's wreck, but you'd be surprised at how well a heater core can cool an engine.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0867.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0867.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0868.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0868.jpg)
This was after the first afternoon of about 2 1/2 hours with my nephew helping me. He's trying to learn more about cars than what his playstation has taught him.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0870.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0870.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0872.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0872.jpg)
Took all of the harness's out without cutting.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0871.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0871.jpg)
On the second afternoon it was just me, so I was able to work without teaching. Took about 3 hours to have her out and the donor rolled out.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0873.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0873.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0874.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0874.jpg)

It wasn't actually as bad as I thought it would be to pull the engine and tranny out together. It's one HEAVY SOB, but came out fairly easily. The worst part was realizing while the engine was hanging on the hoist that the front diff had to drop down an inch to slide the engine out in order to clear the oil pan.

I'm still up in the air as to wether or not to transfer the cluster and BCM over. The only things I see that I will lose that really matter is the tranny temp guage and the tow/haul switch. I already have an older QUADZILLA digital guage for the tranny, and BRAYDEN at FLEECE can write me a custom TCM OS that will allow me to use tow/haul without the BCM. The WIF light can simply be tapped into the sensors output as it is just a magnetic on off switch that grounds a circuit. The wait to start light and check engine light already have there own drivers coming out of the ECM, so they can be wired directly to my existing cluster. The 01 ECM appears to have the correct ABS seperate output and a speedo output, so I should be able to elimnate my VSSB.

I'm sure I'll run into many obstacles along the way, but so far it hasn't been that bad. The ALLISON measures just 1" longer than my 4L80E, and the LB7 block has dual bolt patterns that will accept my old engine mounts. I'm going to do a test fit in the next few days to see if the mounts line up or not in the SUBURBAN, but if my measurements are correct the DMAX is actually not as long as the 6.5 I pulled out. And the fact that they moved #1 over to the passenger side on the DMAX should allow ample room for the downpipe to fit in.

It also turns out that there is a converted 99 C2500 SUBURBAN in VALRICO that has a 01 DURAMAX ALLISON in it. His is a 2 wheel drive, but he said it was a pretty easy swap. His was a 6.5 to start with as well, VS the one the dieselpage did where they started with a 88 1500 gasser. I'm probably being overly optimistic, but I don't want to burn myself out early on in this big of a project.

And here is the recipient just before the 6.5 was pulled.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/HPIM0047.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/HPIM0047.jpg)

[THEFERMANATOR]

This is the thread that got me started on this project.

http://www.thedieselpageforums.com/tdpforum/showthread.php?t=27851

And this is my second update on it.
-------------------------------------------------

Well I worked on it again today and made a little progress. Here is the SUBURBAN stripped down and ready for some test fits.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0879.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0879.jpg)

Here's trial fit #1.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0883.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0883.jpg)

Here's trial fit #5 after several attempts of finding what had to be dropped and cut. Ended up having to remove the front differential, cutting the corner off of the passenger side engine mount pad on the frame, remove the bumper, and drop the steering linkage down.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0886.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0886.jpg)

Here's #7 where I actually got it somewhat close to where it should sit.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0887.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0887.jpg)

And on the 9th try I got it somewhat mocked in and was able to do some test fitting and clearance checking.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0889.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0889.jpg)

Should be plenty of room to move the radiator back and put the intercooler up there as I have over 4 inches of clearance between the fan and radiator.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0888.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0888.jpg)

Unfortunately it looks like I will either have to lift the body 2 inches, OR hammer out the tranny tunnel a bit, possibly switch over to the electric shift transfer case as the shift linkage is RIGHT against the tranny, cut part of the oil pan out and make a notch in it in the front to clear the steering linkage, hammer part of the oil pan in by the differential mounts, and do some more clearancing on the mount pads as to gain some clearance between the block and mount pads. This is a TIGHT fit, but looks doable. The hood will also be tight down to the engine at the compressor it looks like. I was able to get the transmission crossmember and mount in, but the tranny is touching the trans tunnel as it sits now. I'll try and get some more pics of how it fits tommorrow, after 7 hours of putting the engine in and out I was WHIPPED!

[reelapeelin]

I cam imagine you were WHIPPED!!...that "trial and error" thing make s for some tuff goin'..specially swingin' a motor around each time:cen:...

[willy]

That is going to be a monster sub, big project, good luck with it.

[lumberslinger178]

great job ferm ....love them war wagons ,,, had myself an 89 with a 350 ran like and animal:clap:

[THEFERMANATOR]

The old 6.5 ran pretty good, but it always something everytime I turned around that needed work. After the last failure though, it was gonna cost me about $2K in parts alone to nurse her back to health. S o I decided to upgrade a bit to 300HP Vs my old 190HP:sly:, and why not back it up with an ALLISON. This sucker is HEAVY though, my old combo weighed about 1000-1100 pounds and this new combo weighs in around 1500. It's a big old load to swing around by myself.

[Skools Out]

ferm when you're done come on over and we'll put one in my 6.5T Tahoe. As if the rare 6.5 Diesel Tahoe wasn't rare imagine a 6.6 in a Tahoe. looking good so far.

[cterrebonne]

hey ferm, you didnt happen to want to sell the 4l80e? shoot me a pm if so

[THEFERMANATOR]

The 6.5 will be up for sale soon, but I may hang onto the 4L80E. It needs built, but I have a 350 I built for my uncle but he keeps ripping the 4L60E out of it. I hope the current fully built one I did for him holds up for awhile, but he's taken out 2 already, one stock and the next one was a mild build with a HD-2 shift kit. If he tears up the fully built one I just did I'll have no choice but to swap in the 4L80E.

[cterrebonne]

The 6.5 will be up for sale soon, but I may hang onto the 4L80E. It needs built, but I have a 350 I built for my uncle but he keeps ripping the 4L60E out of it. I hope the current fully built one I did for him holds up for awhile, but he's taken out 2 already, one stock and the next one was a mild build with a HD-2 shift kit. If he tears up the fully built one I just did I'll have no choice but to swap in the 4L80E.

same situation here , i just scored a junker one from a salvage yard to hold me over while i build the one that came out of it, hopefully i can beef it up enough to handle the towing i do.

[THEFERMANATOR]

Here's a copy of my latest post on it over at DTR.

Direct link to it: http://www.dieseltowingresource.com/showthread.php?p=126273#post126273

Well I've spent a few more hours on it in the last few days. Progress has been next to nothing really, but I have worked out a few bugs and fitment issues that I was concerned with. I ended up moving the engine forward until the crossmember was bolted into the holes it was for the 4L80E, and putting the trans mount just slightly back from as far forward as it could sit in the crossmember. This unfortunately cut my clearance with the radiator down from 4. 1/2" to about 2". I wanted to move the engine as far back as possible, but it caused clearance issues with the oil pan and steering intermediate shaft. Also it was going to make fabricating engine mounts BEYOND a PITA! I also ordered in Jim Bigleys conversion guide from the page, and I am going to use the foundation of his mount templates for mine. My engine will actually be about a 1/2" furthur forward than his conversion, but at this point many things are revealed.

At this point in time there is NO DOUBT in my mind that the DURAMAX was designed to fit into the older GMT-400 platform. The ALLISON 1000 is another story. With about 5 minutes with a 3lb BFH the transmission now has about a 1/2" of clearance all around, and will have more before I'm done. The indent in the drivers manifold matches the intermediate steering shaft almost dead on. And the oil pan has a clearance spot in it that matches the steering nearly perfectly once you remove the plastic coating from it. Also by sliding the engine forward a 1/2" and lowering it down over the pan notch, it lowered the engine down and the fan shroud lines up almost perfectly center. And by using a 95 mount instead of the 01 on the trans, it brought my pinion and engine angles to within a 1/2 of a degree of each other so shimming shouldn't be required.

I'll have to rework the radiator core support a bit to work with the DMAX intercooler and retain an external trans cooler. The pages truck uses the radiator only in there conversion, and modified the condenser to slide it forward. I plan on cutting the fan shroud and sliding the radiator back an inch and gutting the center of the core support and sliding the intercooler in there.

The electrical appears to be pretty straigght forward as the 6.5 and DMAX use almost the same engine fuses and amperages. I will have to add an IGNITION 1 relay and the ECMPRV 15A and INJ B 25A for the FICM, as well as a 15 A fuse for the fuel heater. The rest are already there, and most of the wiring colors are the same between the 2. I will also have to add in another A/C relay as the 01 ECM looks for a ground from the HVAC controller, but the 95-00 controller in a 6.5 truck sends a 12V+ to engage the A/C. The APPS out of the 01 will not fit into my 95, but my 95 WILL interchange to the 01 ECM as they are both wired and work the same(just a different base with a stronger spring in it).

Now for some pictureshttp://www.dieseltowingresource.com/images/smilies/biggrin.gif.
Steering after grinding the coating off the front of the pan and smoothing the ribs down a bit. Provided an extra 3/8" clearance by cleaning it up, and a total of almost an inch after moving it forward with this cleaning.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0890.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0890.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0891.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0891.jpg)

Heres the steering shaft.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0893.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0893.jpg)

Lots of room between the turbo and firewall for the insulating mat.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0894.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0894.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0895.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0895.jpg)

And a few shots of the ALLISON nestled down in there nice and snuggly. I need to get a pic showing how close the shift rod is the case, it misses it by about a 1/4".
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0899.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0899.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0896.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0896.jpg)

[Mac_Attack]

Good work Ferm! Billy Mac :beer:

[THEFERMANATOR]

Next update.

I'm making a little progress, BUT THIS THING IS KICKING MY ***!! I have spent the past 2 days fabbing the motor mounts and welding em up. The passenger side one is done, but the drivers side warped some from welding. So I have to straighten it some in the press, and weld the last brace into it. Next I'm going to re-inforce the trans crossmember and fix it where I modified it in the past for a GEAR VENDOR install that I took out. That ALLISON is quite a bit heavier than my 4L80E was and the crossmember seems to flex more than I would like with the weight on it. I also am going to have to modify the lower oil pan on the passenger side. GM changed the front diff mount on the later trucks so they could put the kick-out on the side of the oil pan for extra capacity. That kick-out hits the lower mount for the front diff on mine, so I'm going to cut and weld a plate in like Bigley did on his rather than change out the mount for the diff. I dropped the pan earlier before making the mounts and installed the diff to make sure it all would clear, and I had good clearance on it.

I also installed some limiters inside of my factory rubber mounts so the engine can't move as far since it is so tight in there. I'm hoping to finish the drivers mount, trans crossmember, and get the oil pan cut-out made tommorrow. I may take it to a local welder and have him tig it so that I don't have to worry about any leaks in the pan instead of migging it myself. If I can get that done then I'm going to go run some more parts down MONDAY and take a break from it for the day. Then start on the engine and tranny with what I'm going to do to them. I know it needs a FPR on the CP3 as it loped like a cammed big block at idle before, and I found a FORD relay for $13 to fix the glow plug controller with already. I will probably also do head gaskets as I see some signs of leakage around the passenger rear side of the head in between the block and head, and do the injector cups while I'm there.

I'm still up in the air though on the injectors. They currently have roughly 130K on em, but it had ZERO smoking before. The balance rates were less than .5 on 6 and 2 were at 2.5(one positive and one negative). I also plan on a KENNEDY lift pump, EFILIVE(found out the new AUTOCAL will only be for one ECM/TCM combo with no expansion to a second ECM or TCM incase one fails), and an adjusteable boost valve. Also I found a pre bent 4" exhaust that will fit my SUBURBAN so I don't have to modify a truck exhaust to fit. And swap out my 4.10's for some 3.42's, and replace my CV boots.

No pics tonight, been working and getting so greasy I didn't want to mess up my camera.

[THEFERMANATOR]

Got the motor mounts done today, finished up my tranny crossmember and modified the oil pan. Got the engine sitting in there and with it's weight on the mounts.

Heres my finished motor mounts.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0901.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0901.jpg)

Passenger side installed in the truck.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0902.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0902.jpg)

Drivers side installed.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0905.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0905.jpg)

Before installing the mounts I had to take my BFH and flatten out part of the mount clamshell where the motor mount bolt was close and also added in some 1/4" plate to act as limiters to reduce engine movement. The red circle is where I had to flatten the edge off. The blue arrow shows where I added my limiters(theres one in the bottom as well).
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0900.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0900.jpg)

Oil pan clearance with it all together.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0907.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0907.jpg)

No turning back nowhttp://www.dieseltowingresource.com/images/smilies/eek.gif. You can see I had to take a good bit out of the passenger side of the lower pan to clear the diff mount.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0909.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0909.jpg)

And the finished pan after welding, grinding, pressure testing, and paint.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0910.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0910.jpg)

[bradford]

You are the man Ferm!!

[spareparts]

hey, what did you do with the gear venders OD?

[THEFERMANATOR]

hey, what did you do with the gear venders OD?

Long since got rid of it. GEAR VENDORS took it back and refunded my money for it. Never could get it to work without driveline vibrations, and after 4 months of fighting it I returned it. Just something about the combo wouldn't work and made a HORRIBLE driveline resonance that would shake the rear view mirror off the windshield.

[spareparts]

have you seen the new 6 speed auto that TCI has? Its got me interested for the blue truck

[THEFERMANATOR]

The new TCI 6 speed is nothing more than the JET valve body that JET cchips used to sell. They discontinued it due to low sales, and TCI bought it. It simply engages the O/D unit in 1st and 2nd to give you 2 extra gears. O/D is still the same ratio, so it provides no reduction in RPM's on the highway. There are a few companies now working on adapting the new 6 speeds to the older engines. They bolt up and such, but the controllers for the transmission is part of the valve body which means you have to make a box to talk to it since you can't simply use a stand-alone TCM for it.

[cterrebonne]

The new TCI 6 speed is nothing more than the JET valve body that JET cchips used to sell. They discontinued it due to low sales, and TCI bought it. It simply engages the O/D unit in 1st and 2nd to give you 2 extra gears. O/D is still the same ratio, so it provides no reduction in RPM's on the highway. There are a few companies now working on adapting the new 6 speeds to the older engines. They bolt up and such, but the controllers for the transmission is part of the valve body which means you have to make a box to talk to it since you can't simply use a stand-alone TCM for it.

that would be sweet a better trans on a 5.7

[spareparts]

yeah, the picture looked like a cross between a th400 and a 700R4

[cterrebonne]

yeah, the picture looked like a cross between a th400 and a 700R4

they should have somthing that would replace the 4l60e. the 4l60 should be a elec version of the 700r4. it would be cool, then my 1500 could do some towing.

[Skools Out]

they should have somthing that would replace the 4l60e. the 4l60 should be a elec version of the 700r4. it would be cool, then my 1500 could do some towing.


just put a 4L80 or 4L80E which ever you need you won't break an 80 towing your 1500 can't pull more than the 80 will handle.

[Skools Out]

Ferm and I, well our diesels have the 4L80 in them, that's a strong trans, they were rated at able to handle 1000 hp and 1200 ft tq.

[THEFERMANATOR]

Mine HAd one, now it's backed by a much larger soldier.:sly:

[cterrebonne]

Ferm and I, well our diesels have the 4L80 in them, that's a strong trans, they were rated at able to handle 1000 hp and 1200 ft tq.

yeah thats what it looks like i need to get, is there anyway to build a 4l60e to handle what a 80 can?

[Skools Out]

nope that 80 is a larger case and all totally different pan and carrier set up

look at the junk yards for a 2500 Suburban with a 454 BBC or 6.5TD also a 2500 to 3500 GM truck with either the 454 or the 6.5TD has them in them

[THEFERMANATOR]

yeah thats what it looks like i need to get, is there anyway to build a 4l60e to handle what a 80 can?

A max build on a 4L60E can take just about the same as a stock 4L80E. A shift kit in the 80 though and you are WAY ahead of what a 60 can even think about. The 60E can be a decent tranny for a small block, but requires some work to get it there. A TRANSGO HD-2 shift kit, HUGE tranny cooler, ALTO clutches except for the 3-4 pack(the Z-pack is the way to go there), heavy sprag and one way clutch stator, 10 or 13 vane pump, corvette servo or SONNAX billet servo's(even better, but shift HARD!), SONNAX 1-2 shift valve, deep tranny pan, and a SUNCOAST billet converter will get you a stout 4L60E. You'll be looking at around $1300-1500 worth the parts alone though. Depending upon the year of your truck, an 80 will most likely be easier to swap and be less money.

[cterrebonne]

yeah thats what its looking like, im findind 80's for about 600-700 on the net from the parts finder site i got my 60 from. i sure i can unload one of te 60's at least half the cost of the 80.

[THEFERMANATOR]

What exactly is the truck your having problems with?

[cterrebonne]

no problems anymore since i put the new trans in. but its a 97 k1500 w/ the 5.7
how it all started was the truck was for the dealership where i work that the boss would drive to and from his house and we would use it sometimes to pull boats to the launch to run. at 90k miles the transmission went, i think the sun shell broke at where the splined collar is welded to it or so what the trans guy said. well he rebuilt it and 30k later it was making noise in just rev/1st then on the way to work i lost OD and then i lost all forward gears and reverse would work but go out. when i tow the v-20 its 80 miles one way.

[THEFERMANATOR]

Sun shell failure is unfortunately common, but the BEAST sun shell takes care of that. ANY 4L60E build(and 700R's) should include a BEAST, it's the best $60 you can spend on one. If your running a stock 97 with even a 350 in it, a 4L60E should be plenty. Put a bigger cooler on it, TRANSGO HD-2 shift kit, 1-2 shift valve in the valve body while your there, and swap out the 2nd servo with a corvette servo while doing the kit as well. That will get you ALOT more holding power. Also reducing tranny temps and keeping them under 200 will make it live a happy life, anything higher and they don't last.

[cterrebonne]

you would have thought that the guy would have at least installed the beast, but after i spoke with him he seems a little shady. i bought the dvd and atsg's manual for the 4l60e. thanks for the tips on beefing up rebuild. this summer i'll probably rebuild the one i removed with all the mods and wait for the new one to go out but i definately need to install and temp guage. also ferm i have a trans cooler and its kinda big, but how big of one should i run?

[THEFERMANATOR]

The factory one is pretty good if it has the optional towing one. GM ran the 11" wide by 4" tall one on some and a 6" tall on others. The problem I have seen though is the way GM mounted it. The inlet and outlet are both on the bottom, and I have seen them get slightly plugged and not flow through but the bottom 2 or 3 rows on the cooler. I rotate em 90 degrees and feed it through the bottom and out through the top, this way you know that you are using all of the coolers passages. I like this cooler as an easy add on one as it comes with line and adapters to hook right to the radiator. You could even hook it up along with your current one for extra cooling.
http://store.summitracing.com/partdetail.asp?autofilter=1&part=BMM-70264&N=700+4294924500+4294839034+400004+115&autoview=sku

[cterrebonne]

hmmm...my cooler is about that size of the summit one. i removed my grill and was inspecting it i can put a tape on it tonight to see ,but it was quite large. it pretty much filled up the left side of the radiator with a little room up a the top. i think ultimately i need a temp guage to keep the temps in check.

[spareparts]

now that we are on the subject, what would be involved in swaping out a 60e to a 80e in my 99 1500 Suburban. Its got 175k on it, I've changed the fluid on a regular basis. We bought it with 80 on it, so I don't know if the transmission was done before we bought it or not. We live in flat land and I've rarely towed anything with it(that may change). I figure when it hits 200, I'll start on the fresh block I have in the garage( have a fresh set of vortecs as well), I'll probably throw a little cam in it, with some good valve train, but otherwise leave it pretty tame. I might as well take care of the tranny while I'm at it, and I like the idea of towing in OD. I want the computer to work well with everything

[THEFERMANATOR]

99 is a fairly easy swap really. The tranny bolts right up to the block, but the input shaft in the transfer case is different as a 60 uses a 27 spline output and an 80 uses a 32 spline shaft. You do have to change a couple of the pins in the trans plug, and I believe you have to run one wire from the PCM to the tranny. Then you have to have a 2500 program flashed into the ECM for one with a 4L80E as one of the solonoids in the 80 works backwards from the 60 as well as the gear ratios are considerably different between the 2.

[THEFERMANATOR]

Back on topic.

Been a slow couple of days lately. I had to go run errands MONDAY, so I only got the oil pan back on it after putting JB weld over the seems for insurance. Went out today and built a stand for the engine and an adapter to put the tranny on my engine stand to make it easier to work on. Unfortunately I had a mishap today and broke my wiper motor cover and housing when the studs for the glow plug controller caught it when the engine swung sideways on me coming outhttp://www.dieseltowingresource.com/images/smilies/mad2.gif. Fortunately I priced out an aftermarket one for $68, so at least it wasn't TOO expensive.

Here's the oil pan epoxied over at the seems and everywhere that I had taken the paint off.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0912.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0912.jpg)

The engine sitting on it's stand.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0913.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0913.jpg)

And the ALLISON on the engine stand.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0914.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0914.jpg)

And my mishap.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0915.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0915.jpg)

Sure is empty looking without the powerplant.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0916.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0916.jpg)

[kamikaze]

Interesting note about the beast sun shell. I went through four different 700R4 rebuilds (Not by me..) for what turn out to a problem related to the sunshell. The Beast comes with a small washer that MUST be installed or else you'll be swapping out the tyranny in no time for another one. Just ask the guy who keep rebuild mine over and over and over.... Worked great after he finally figure out it was just a extra part...:oh:


Kamikaze

[cterrebonne]

that d-max is a beast

[Skools Out]

now that we are on the subject, what would be involved in swaping out a 60e to a 80e in my 99 1500 Suburban. Its got 175k on it, I've changed the fluid on a regular basis. We bought it with 80 on it, so I don't know if the transmission was done before we bought it or not. We live in flat land and I've rarely towed anything with it(that may change). I figure when it hits 200, I'll start on the fresh block I have in the garage( have a fresh set of vortecs as well), I'll probably throw a little cam in it, with some good valve train, but otherwise leave it pretty tame. I might as well take care of the tranny while I'm at it, and I like the idea of towing in OD. I want the computer to work well with everything


why do you change the fluid? you shouldn't change the fluid in a GM trans as they will tend to shorten their lives. My L80 never had the fluid changed till the torque converter got noisey, that was at 218,000 miles. the trans shop plus 2 ASE Cert. said don't change it as long as your fluid stays red and clean run it. if the fluid gets dark then you have an issue in the trans. I changed it in 3 other of my GM products in the past all had short lives afterwards. On a trans go with the old rule if it ain't broke don't fix it. just change the trans fluid in the transfer case when it tends to clunk from stop lights.

[parishht]

Actually, my wife's CR-V has to have the fluid changed every 36,000 miles.
HONDA knows of the problem, put out a service bulletin that admits the problem,
but will only pay for one change, after that we have to pay.

[Skools Out]

lol that's a rice burner though not a GM trans

[cterrebonne]

im sure those techs knwo what they are talking about but it doesnt seem to make any sense to me. you only change half of the total fluid anyway and i dont think a filter would hurt anything. in my case my trans was making noise before and after so i dont know

[Skools Out]

there's fluid in certain areas they stay in place and hold valves in place but once you drain the pan then if the chance those vlaves move due to no fluid they might go the wrong way then keep fluid in incorrect areas of your trans which then cause's it to die fast and early, the rule is in 3,000 miles after the fluid change you will either still be running or pushing. don't you think if they wanted or thought the fluid needed changing they would have installed a drain plug? there's no drain plug in a trans on the GM stuff.

[THEFERMANATOR]

there's no drain plug in a trans on the GM stuff.

Many of GM's trucks came with drain plugs after 97, and my ALLISON DEFINATELY has one. I for one personally believe in changing the fluid AND filter every 30K for a daily driver, and every 15-20K for a vehicle that gets worked. I've seen WAY too many GM trannies get diagnosed as bad or fail because of lack of maintence. And when I was at DODGE you could tell if one hadn't been changed by how loud they were on a cold start. After about 40K miles the tranny will howl on a cold start if the fluid hadn't been changed. The problem with fluid changes is if you haven't kept up on it by the book, then don't do em at all. Once you go more than 30K without a fluid and filter change you will get particle build-up inside the valve body. If you change the fluid and filter after this has gotten built up, the fresh additives in the new fluid will almost certainly clean that build up out and deposit it in areas you don't want it.

[cterrebonne]

[QUOTE=THEFERMANATOR;The problem with fluid changes is if you haven't kept up on it by the book, then don't do em at all. Once you go more than 30K without a fluid and filter change you will get particle build-up inside the valve body. If you change the fluid and filter after this has gotten built up, the fresh additives in the new fluid will almost certainly clean that build up out and deposit it in areas you don't want it.[/QUOTE]


thats pretty much the mantra i use for them. i was only at 30K after the rebuild when i changed the fluid.

[msbhammer]

Good job Therm. I dont know crap about working on vehicle.

[THEFERMANATOR]

Latest update.

Progress had to slow down unfortunately this weekend as I had honey dos on Saturday and my asthma flared up yesterday. I did get to work on it for about 4 1/2 hours on Friday and was able to get the top half of the engine tore down. This engine is nowhere near as hard to work on as I thought it would be, or maybe the fact mine is on a stand makes a difference. The passenger side head gasket at the rear most coolant passage was just beginning to leak as I had the nice white chalk line on the back of the block below the gasket, and you can see the rust line in the pics on the gasket and the block. Also found that cylinder #2 was showing signs of washing down from fuel and the injector tip on that cylinder was pretty rough. 1 glow plug is burned out and 2 others look rough as well. I pulled the injectors apart and cleaned them with some spray cleaner to see what makes em tick inside, and they are actually pretty simple internally.

Here's the engine with the heads off.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0920.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0920.jpg)

The heads on the bench with the injector cups out.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0918.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0918.jpg)

right side gasket at the rear.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0919.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0919.jpg)

And the block in that spot.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0923.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0923.jpg)

This picture shows how #2 showed signs of a leaking injector as the bottom of the piston is very clean.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0921.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0921.jpg)

This may explain part of GM's troubles. This is the turbo intake horn gasket, that big ole MOPAR box for that little gasket.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0917.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0917.jpg)

And the innards of the infamous LB7 injectors.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0924.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0924.jpg)
You have the nozzle, a needle valve that rides inside of the nozzle, then the plunger that rides against the needle valve and the return spring and the spring seat that sits inside of the injector body. Inside of the injector body is a metal tab that protrudes through the spring and this is what pulls the plunger back to let the needle valve open and allow fuel through. And the 2 little pins are the locating pins that hold the nozzle in place to prevent it from turning. My camera couldn't focus on the insides or else I would have put up a pic of that as well. When I pulled it apart the needle valve was just about frozen into the injector nozzle body and required soaking to come apart. Once apart it cleans easily with spray cleaner and I re-assembled with marvel mystery oil. Debating on wether or not to replace them or have these tested and run them.

[cterrebonne]

man diesel engines rock.

[THEFERMANATOR]

I've been slacking a bit lately on updating this thread over here, so I'll try and bring it up to speed. And now that my wedding is over I can hopefully get back on this full time and get er done.

[THEFERMANATOR]

Things still going slowly as my money will be tied up until the middle of MAYhttp://www.dieseltowingresource.com/images/smilies/mad2.gif. I've got my gasket sets coming along with head bolts, glow plugs(3 were bad), water pump, and will order my injectors when my money gets freed up again. I also got my trans kit and ordered my ALTO clutches and TRANSGO parts, and will get my precision converter next month as well. Found out you can piece a SC3 together on your own for under $700 VS suncoasts $965. I'l also be ordering my EFILIVE as soon as money is available as well. Also picked up my manual shift transfer case on TUESDAY from ORANGE CITY while I was out picking up my left side head gasket(GM is on backorder for left side grade B's, but a dealer in OCALA had one in stock). And my ring and pinion sets should hopefully be off backorder the first of the month as well.

Now I have to go back to working on other peoples stuff so I can afford mine againhttp://www.dieseltowingresource.com/images/smilies/sad.gif. Hopefully the end of MAY and the drivetrain will be done.

[THEFERMANATOR]

Things unfortunately have had to slow down as my finances ran out, but I have that back in order now and am getting back on to this project as much as I can. I'm getting married the end of this month, so progress will be sporadic. The engine is most of the way back together, and the PENSACOLA remans are in it. MOST of my parts are in or will be in this week. I still have to iron out my air intake set-up as a standard DMAX one will run the hood, and the fatermarkets sit even higher. And I will most likely be calling DIAMOND EYE for my exhaust as they are the only ones selling a true 4" exhaust for a SUBURBAN for a reasoneable price, and will probably go with a CORSA muffler as exhaust drone will be a concern. My front and rear gear sets are finally in after waiting 3 weeks for them to get off backorder from AAM, and PRECISION will be shipping my converter out tommorrow. DACCO in TAMPA got me all of the ALTO powerpacks, converter flow valve, TRANSGO shift kit, and an ATSG manual for $721 after taxes and freight. I also got in my KENNEDY wear plate for the T-case, and a KENNEDY lift pump as I liked his design better than the TTS.

Unfortunately though I have to get the engine, trans, and front diff done before I can get the engine bolted back in as the puzzle will be tight and dizzying to get them all in there. Still hoping that I can have it running by the first of next month though, wish me luck.

[THEFERMANATOR]

Well the engine is back together, and the transfer case has the wear plate installed in it. Unfortunately the input and rear output shaft seals that the aftermarket carries don't fit the XHD case, so I have to go to the dealer in the morning to get those(the front output fit perfect though). My PRECISION converter will be in tommorrow, and I have the rest of the trans parts already. My new radiator came in today as well from CARQUEST(my discount got it down to about $430 vs AZ's $500), but the UPS people looked like they played football with ithttp://www.dieseltowingresource.com/images/smilies/mad.gif. The box had several holes in it, and the fins on the engine side of it were almost all flattened out. Not to mention it had 2 BAD spots where it had stuff sat on it and flattened out the tubes(one spot had cracked the tubes). So I'm waiting on another radiator as I wouldn't take this onehttp://www.dieseltowingresource.com/images/smilies/mad2.gif. I also got m yEFILIVE ordered today from FLEECE, and they are supposed to be flashing my TCM tommorrow so I can get it back next week.

If I had it to do over again though, I would just have bought an 01 2500HD pick-up and put a topper on it. MAN this is ALOT of work to work out the details.

Not many pics as I keep forgetting the camera in the house while I'm in the shop. I walked out and snapped a few though.
Heres the engine back together.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0943.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0943.jpg)

And the parts are beggining to take over my shop. This is about half of what I still have left for parts to go in it.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0944.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0944.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0945.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0945.jpg)

[THEFERMANATOR]

Transfer case is done now, and the front diff has 3.42's in it now as well. I decided to pull the front axle shafts out and do the CV boots while I was this far into it since they are 14 years old, and I also packed some grease into the front hub bearings while I was at it.

My other half is busting my balls over this though.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0952.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0952.jpg)
My new PI converter came in and she said my SUBURBAN is now gay since I am putting something in it that is yurple.

[THEFERMANATOR]

Problem #999 or 1000 on the list. I got my tranny all apart and cleaned up for the most part and began re-assembly. Ran into some problems with my ALTO powerpacks. The C1 pack is roughly .041 thicker than my old pack, the C2 is .031 thicker, the C3 is only .005 thicker, and the C4 is .027 thicker. The problem is that C2-C4 aren't adjustable, they just have a range that they have to fall into. The C3 and C4 shouldn't be a major issue I don't think, but C2 is. The clearance range on the C2 is .070-.085 according to ALTO, and I have .023 now. I can get a new plate for the C1 to correct it, and I still need to try the C3's and C4's to see how they fit in yet. I'm going to re-use the C5's as all of the old clutches still looked brand new after 162K miles, but all of the sealings rings and apply pistons were hard as a rock. So it looks like my money saving build will actually cost in the endhttp://www.dieseltowingresource.com/images/smilies/mad2.gif, so much for trying to save $300 by piecing it together myself.

[THEFERMANATOR]

Trans is done now. Got it all back together and everything measured out within speck except my C1's were a little tight(I have .082" and MIKE reccomended .090-.105, the next plate thinner would have given me .125 though). Still waiting on my connectors for the trans lines though, the GM parts book lists the wrong ones for an 01 so I hope he got me the right ones comin now. I'm hoping tommorrow I can get it close to going back in the BURB.

[THEFERMANATOR]

Got some more done today.

Here's the trans all finished up with my yurple converter in it.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0958.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0958.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0959.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0959.jpg)

And the two mated back together just about ready to go in the BURB.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0962.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0962.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0963.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0963.jpg)

I got the new firewall sound pad installed today and hopefully tommorrow I can get a little welding done and slide her in for the final time.

[THEFERMANATOR]

Well today was a productive day. Got the engine and tranny back in the BURB, installed the front diff, transfer case, and the front driveshaft. Got em all in and tightened down and most of the accesories on it as well and filled the front diff, engine, transfer case, and tranny up with fluids. My next BIG project will be wiring followed by installing my intercooler, then installing a 1/2" feed line from the tank up to where ever I mount the lift pump at, and then swapping out the rear gears to 3.42's. I also called up ALLIGATOR PERFORMANCE and ordered a CORSA muffler, DIAMOND EYE 4" SUBURBAN exhaust, and an AFE stage 1 intake. My EFILIVE came in last FRIDAY as well as a new 1410 series yoke for my 14 bolt. Hopefully my TCM gets back from Brayden here soon as I will need it once the wiring is finished up.

And now for some pictures.

The engine bay with the new sound pad installed.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0964-1.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0964-1.jpg)

And later on in the day it all came together.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0965.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0965.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0966.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0966.jpg)

It's a TIGHT fit, but you can just get to the fill plug to fill her up with fluid. I did have to grind alot of the ribs off of the extension housing though to get clearance on the torsion bar crossmember.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0971.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0971.jpg)

And the 01 front driveshaft dropped right in and fit perfectly. You can see in the pic though that the shift lever for the transfer case is just barely missing the tranny, so I will have to grind part of the transmission mounting boss off to clear it.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0969.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0969.jpg)

[cterrebonne]

awesome job man.

[nymack66]

I promise I will NEVER referred to my outboard work as a "Project" again after reading this post.
You are doing one heck of a job here , not in my wildest dreams will ever manage a project like this.
Good Luck and keep us posted

[THEFERMANATOR]

I promise I will NEVER referred to my outboard work as a "Project" again after reading this post.
You are doing one heck of a job here , not in my wildest dreams will ever manage a project like this.
Good Luck and keep us posted

There all projects, I sort of turned this one into an adventure though.

Today's update.

Well I started the day by removing the fuel lines from the donor and putting them in the shop to put on tommorrow. Then I decided to tackle the wiring and get started there. Managed to get most all of the old engine wiring out and most of it laid out as to how to put the new back in. I also pulled the cluster out and redid the glow plug circuit as my 95 powered it but the DMAX grounds it.

The cluster is out and wiring getting sorted out.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0972.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0972.jpg)

The cluster before.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0973.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0973.jpg)

And after. You can see the jumper I installed to the power that would have been for the DRL(my 95 doesn't have daytime running lights) to where it used to be grounded. Picking the copper off the plastic is alot more work than you would think to boot.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0975.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0975.jpg)

Midway through cutting out the engine and uneeded connectors.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0976.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0976.jpg)

End of the day. Got almost all of it out and can start taping it back up tommorrow after I fix some of GM's SH!TTY splices. No wonder these trucks have developed so many grounding issues, GM did some HORRIBLE splices inside of the wiring harness's.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0978.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0978.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0977.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0977.jpg)

I always end up with a few extra pieces after a project like thishttp://www.dieseltowingresource.com/images/smilies/hihi.gif.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0979.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0979.jpg)

[willy]

Ferm I think you have forgotten more than most of us will ever even know.
Hope it goes smooth from here for ya

[THEFERMANATOR]

Ferm I think you have forgotten more than most of us will ever even know.
Hope it goes smooth from here for ya

I sort of got an early start on teething myself with wrenches.

http://i162.photobucket.com/albums/t271/THEFERMANATOR/1.jpg

[THEFERMANATOR]

Don't have any pics, but I have been busting my tail on this thing all week. My pins for the fuse block just came in today so I can get back to wiring again soon. While I was waiting on my terminals for the fuse panel, I decided to hook up the transfer case shift linkage and I also got a shift linkage mount bracket fabbed up. the DURAMAX shift cable will not hook up to the early cloumn, so I had to buy a new shift cable(mine wouldn't stay on the shift arm as the nylon in the end that locks it on was worn) and custom fab my bracket as the 95 cable is 2 inches longer than the DMAX cable from the mount point to the shift arm. It is pretty tight under there as the 2" setback put the cable mount RIGHT next to the U-joint for the front shaft. I was able to get a 1/4" of clearance on the crossmember and a 1/2" on the shaft(may ned up bringing it in closer to the shaft if it hits the crossmember). So I can now shift it through it's gears in the trans and transfer case.

I pulled the tank out and removed my 5/16" return line and opened it up and installed a 1/2" feed line and will use my old 3/8" feed for my return and I have the fuel cooler off and am about ready to mount it under the truck as well as my KENNEDY lift pump. I discovered that the DMAX metal lines will not clear the steering linkage on my SUB, so I hooked up my nylon covered diesel line right to the quick connects and was able to get them over the lock portion so I could double clamp em on there. And I will just use nylon covered diesel flexible line for the bulk of the fuel system. The tranny cooler metal lines didn't clear my front axle mount with enough room for mmy liking even after some tweaking, so I got some AN hose and AN fittings and will just plumb the cooler system that way. This really sucks as I had already had the original lines done up with hydraulic line in place of the old rubber line.

While the fuel tank was out I did the rear gears today since that BIG opening made getting to the diff EASY as piehttp://www.dieseltowingresource.com/images/smilies/biggrin.gif. The GM 14 bolt 10.5" rear axle is actually pretty easy to build compared to the DANAS and CHRYSLER corporates I am used to building up. The tough part was torquing the pinion nut. This required a 4' 3/4" breaker bar and socket to match and locking the pinion yoke down in my vise. This allowed me to stand on the bar as my impact with 600 foot pounds could BARELY budge it(I had it in the press to install the front bearing and bring up the slack to the crush sleeve, even at 6 tons of pressure the crush sleeve didn't compress). It looks like I lucked out as my G80 looked BRAND NEW inside. I went ahead and pulled it apart and inspected the governor, and all the clutches were good and tight and all of the governor teeth were intact. I'm going to pull the rear hubs tommorrow and replace the axle seals since I'm this far into it. And hopefully get the fuel system plumbed as well.

I got my shipment from ALLIGATOR today, and will hopefully get my TCM tommorrow. That CORSA muffler is one BIG SOB now, espescially compared to the diamond eye that came in my exhaust kit. So I will have a 6.5 3" downpipe and a 4" straight through muffler for sale soon. Little by little I'm getting this thing tackled, but it's the little details that will KILL you in a project like this. I spent almost 2 hours trying to bend and fit the fuel lines in only to find they wouldn't clear the steering linkage after doing ALOT of bending and cutting on em. And you don't realize how much time you can spend bending and fitting a 1/2" feee tube and soldering and epoxying it in. The best way to describe it is an old saying we used in drag racing, "OEM = A complete list of all items that MUST be replaced or modified when building a performance vehicle."

[THEFERMANATOR]

Time for my next update, I'll try and get a few pics tommorrow for my my next update. The fuel tank is back in and my 1/2" feed and 3/8" return are plumbed and my fuel cooler is hung right behind the frame support crossmember. Got my KENNEDY pump in and wired and primed it to the CP3 and found no leaks in the system. The rear end is finished up and new wheel cylinders installed. My TCM is supposed to be in MONDAY according to UPS tracking(the TCM was overnighted on FRIDAY, but UPS decided mine was important enough I guess), and hopefully my driveshaft is done as well. The majority of the wiring is done except for hooking up my relays in the PDC and wiring in my toggles and cruise switch inside the truck. I'm running into TAMPA tommorrow and hopefully my driveshaft is ready and I'll pick up some more hose and cushion clamps to finish up my plumbing.

I took it easy today after putting in several 14 hour days and nights trying to start her up this weekend. Hopefully tommorrow I can fire it off so I can verify my wiring and new injectors, but I'm not going to rush it.

[willy]

Good luck, don't rush it brother, now is when the mistakes can happen as I am sure you know

[THEFERMANATOR]

Good luck, don't rush it brother, now is when the mistakes can happen as I am sure you know

I made a few tonight, but it didn't end that badly:party:.

Tonights update.

I don't have many pics tonight, but I did make some headway with it. I got impatient today so I got the harness mostly finished up and decided to do a test fire to make sure it was all working properly. Well the first 3 attempts it just wheeled over and wouldn't fire a lickhttp://www.dieseltowingresource.com/images/smilies/mad2.gif. It was building rail pressure and such, and I had disabled the theft system with EFILIVE. So after about an hour of head scratching it dawned on mehttp://www.dieseltowingresource.com/images/smilies/33.gif, I had disconnected the FICM because I was doing some welding on the downpipe hanger on the engine. Hooked up the FICM and after about 3 seconds of cranking she came to lifehttp://www.dieseltowingresource.com/images/smilies/thumbsup.gifhttp://www.dieseltowingresource.com/images/smilies/banana.gif. After about 20 seconds of running it must have learned the new balance rates a bit and started smoothing out it's idle and sounded pretty good. SO hopefully this will give me a second wind and I can get this thing wrapped up soon and on the road.

Now for a few pics.
Heres the harness mostly together and ready for a test fire.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0982.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0982.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0981.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0981.jpg)

Heres the new location for the glow plug/intake heater fuse. It is right underneath and in front of the ABS pump and right behind where the drivers side battery will go. This also helped in the problem that the DMAX battery cables has too short of a lead to reach to my PDC for my 95, so I used the fuse block as a junction block and hooked on the 6 guage cable from the old harness on the battery side of the fuse block and this got me a good power cable to the PDC.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0983.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0983.jpg)

And heres the PDC almost finished up. I ran out of tape so I couldn't put the flex covering over it tonight. Didn't come out to bad for a spliced together mess.(And don't ask me how many solders and splices I had to make in that one little area, it's a good thing that I like electrical)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0985.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0985.jpg)

And a special treat, the audio sucks but you get the idea.
http://s162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/?action=view&current=HPIM0984.flv

[willy]

Sounds like a road trip coming

[THEFERMANATOR]

I had a shorter day today as I have to go down tommorrow and get one of the new exhaust pipes expanded so it will fit onto my CORSA muffler. I got MOST all of the wiring in and done today as well as the driveshafts. Since I needed to have the pipe done I decided to take my time and make the wiring as neat as possible. After finishing up the wiring and putting the shafts in I started her up and put it in gear to see if it would go in and it dropped into forward and reverse right away. I also did 3 starts on it with no check engine light so I may be OK in the MIL department. The tachometer works fine since I am driving it off the alternator just like a 6.5 did. I still need to check my speed outputs as I decided to try and use the ECM's and bypas the VSSB(if they don't work I left the wires there so I can hook it back up).

Heres a shot of the engine with the harness's in place(ECM and TCM will be mounted last after everything is together).
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0986.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0986.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0987.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0987.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0998.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0998.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1000.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1000.jpg)

Heres the PDC all finished up.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0988.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0988.jpg)

And I spent some time and made an updated insert to go in my PDC for correct fuses and relays.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/95fuseblock-A.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/95fuseblock-A.jpg)

My toggle switches in and my QUDZILLA guage.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0990.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0990.jpg)

The fuel cooler and you can also see the driveshaft.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0993.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0993.jpg)

And a few underside shots to show how tight the fit is.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0994.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0994.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0996.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0996.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0997.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM0997.jpg)

[cterrebonne]

that sub is going to be a beast

[Stinky_Hooker]

You are an evil genius!!! :beer:


"Frankenburban"

[THEFERMANATOR]

"Frankenburban"

I may have to steal this one STINK, it fit's.

Today's update.

Well I got the exhaust finished up yesterday, and I spent today cutting away at the radiator support to fit the DMAX intercooler and radiator in. It is a TIGHT fit between the radiator and fan clutch, but after about 4 hours of cutting and modifying I was able to get enough room to put the fan clutch on with the radiator in place which leaves me an inch of clearance between the clutch and core and 2 1/4" from the fan blade tips to the core. I decided to make it a close fit and severely modify the radiator support to accomadate a stock cooler and radiator rather than modifying the radiator, intercooler, and support. Once I get it boxed back together it will be plenty stout as I can sit on it now without it buckling and I am no where near done reinforcing it.

Here's a few shots of the exhaust. That 4" pipe looks HUGE compared to my old 3" pipe I had before.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1002.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1002.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1001.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1001.jpg)

And the CORSA muffler is a MONSTER compared to the 4" DIAMOND EYE that came in the kit. I ended up having to relocate the front hanger forward so I could move the muffler forward and I had to modify the middle hanger some to allow this as well.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1003.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1003.jpg)

Not a job for the timid.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1007.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1007.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1009.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1009.jpg)

Removed just a little bit bit of metal from it so far.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1008.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1008.jpg)

[THEFERMANATOR]

I guess I've been slacking on updating this one. I got to driver today and feel her out a bit and the power of the DMAX is SWEET in this SUB. It has more power with 3.42's in it than my 6.5 EVER had with the 4.10's. I have run into a few bugs that have to be ironed out though. I'm leaving on my honeymoon on WEDNESDAY, so thankfully I have a back-up vehicle for my trip.

First off the heater return pipe from the heater cores to the lower radiator hose developed a leak in it right at the weld for the retaining arm.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1014.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1014.jpg)

So I'll have to get a new tube for when I get back. Also I have 2 codes that won't go away that I can find no reason for, P0748 and P0778. Also I have very little power in 1st gear and lots of blue smoke if I giver her more than about 20% throttle. This only seems to happen in 1st as 2nd and 3rd pulled VERY strongly. Also my tow/haul mode isn't functioning properly as it gives me VERY hard shifts when engaged and holds them out ridicuously long and provides NO grade braking what so ever. I wasn't able to get her up fast enough where I was driving to test out the OD/LO function.

The A/C doesn't engage for some reason so I'll have to do some digging tommorrow with EFILIVE and see if I can figure out why the ECM isn't commanding the A/C relay(A/C works when I jumpered it).

Heres a pic showing the TCM and you can see the ECM as well tucked in by the drivers side battery tray.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1011.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1011.jpg)

I haven't finished up the airbox yet, so for now the filter is just laying in there.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1013.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1013.jpg)

Another engine bay pic.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1012.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1012.jpg)

And a pic of the front end with my projector headlights. I did have the grill and such on it, but had to take it back off to get to the bolts that hold the drivers battery tray in place.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1010.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1010.jpg)

Hopefully I can get ahold of Brayden before I leave and get his opinion on what to check for the 2 codes and also about low power in 1st as I think it is a torque management issue.

[THEFERMANATOR]

Got one more bug figured out this morning. WONDERFUL ALLDATA got me again. I charged the A/C but the compressor wouldn't turn on. I dug up everything I could from ALLDATA about the A/C trigger and it clearly said that it looks for a ground from the A/C control head to trigger the compressor, THIS IS FALSE! It looks for a 12V+ signal to trigger the compressor to come on. So now I have to go back into my PDC and remove the A/C request relay and hook the A/C sense wire up to my A/C request wire from the 95 head since it powers the circuit on.

[THEFERMANATOR]

And I was asked on the other forum things I would have done differently, this is a short compilation.

First I would do a 2" body lift and raise the engine up 1". Second I would move the torsion bar crossmember back 1" like the guys who do CUMMINS swaps do and then slide the assembly back 1". After doing this swap I would do the dash swap with it if I ever did another. The custom TCM and other hassles isn't worth it. If somebody could make an interface box to allow tow/haul mode like the factory did with the BCM then I would go this route like I did. The DURAMAX intercooler does fit after MASSIVE amounts of radiator support work, but I think a modified CUMMINS IC would be a better option like BIGLEY did with his. Any way you slice it this is NOT an easy swap, and you WILL encounter MANY hurdles and challenges. And don't try to always take what seems like the easy way out as in the end it could bite you in the but. I encountered this with the power steering lines, fuel lines, and trans cooler lines. I ended up going with AN lines for the tranny, and the good hard nylon cored with cotton wrapped fuel lines, and mixing and matching the power steering lines.

And a donor vehicle is a MUST in my opinion. You will be pulling your hair out trying to piece evrything together from one of the EBAY deals. Also a newer SUBURBAN would be a MUCH better option to do this swap as the wiring is almost plug and play for most everything in it.

[THEFERMANATOR]

Well after fighting with PENSACOLA DIESEL remans for almost 2 months of the engine not running right, I went and bit the bullet and bought a set of GM remans. Now she RUN'S:happy:. So here's a copy of my latest post about it now that I'm almost finished up with it.

Since it's about 95% done now I took some pics for the insurance company today and figured I would put em here as well. I still have to finish up the air filter mount, put yet another shift shaft seal in the tranny(can't figure out why it is fine for a few eeks then starts leaking, this will be the 3rd seal) and get the windshield leak fixed. Most of the front end is back on and it's in mostly driveable condition as well though and waiting for insurance and a tag so I can go break her in a bithttp://www.dieseltowingresource.com/images/smilies/biggrin.gif.
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1042.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1042.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1044.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1044.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1045.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1045.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1046.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1046.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1041.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1041.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1047.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1047.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1051.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1051.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1050.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1050.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1048.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1048.jpg)
http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1049.jpg (http://i162.photobucket.com/albums/t271/THEFERMANATOR/DURAMAX%20ALLISON%20conversion/HPIM1049.jpg)

[Blue_Runner]

Is that a K&N air filter? I just cleaned and re-oiled mine on my white '96 GMC 2-door Yukon. Looks A LOT like your burban! I'm hoping to see my gas mileage get better......seems to be working!

Nice job! And pics :pic: Even though I'm not mechanically inclined and could only understand about 1/4 of what you were talking about!

:train:

[THEFERMANATOR]

It's a AFE PRO DRY S filter that uses no oil and filters better than most oiled filters do. If theres any questions feel fee to ask, I can break it down for yeah quite a bit. I just got through playing with my EFILIVE and my 1st custom tune. I have a few issues in it to work out, but let's just say this thing wil flat out MOVE!

[lumberslinger178]

frem you have a gift.....:clap:

[willy]

the beast has risen, long live the beast:clap:

[THEFERMANATOR]

After posting this earlier I went out and loaded in a tune I built with EFILIVE for the engine, let's just say that an extra 50-60HP makes a WORLD of difference:drool:. It still runs with zero smoke, but will flat scoot right along for a big ole beast.

[Bygracealone]

Very Impressive Ferm!

Man, between you and Skools, there's nothing that can't be done with cars or boats. Next, you guys will be building planes...

[THEFERMANATOR]

Very Impressive Ferm!

Man, between you and Skools, there's nothing that can't be done with cars or boats. Next, you guys will be building planes...

No planes for me, that is my uncles and grandfathers deal. My grandfather got into aviation in 62 and got out in 84. Heres a pic I found of my uncles plane on the web. It is a CESSNA 195 that was origanally modified from the 270HP engine to a 450HP engine for arial photography. He got this one because when my grandfather was in aviation he used to run a skydiving outfit and used one just like this for jumpers.
http://gallery.photo.net/photo/3378726-md.jpg

Heres a shot of my grandfathers plane that has been restored.
http://futurshox.net/planes16/sfsh-c195-n4395n-67.jpg

[spareparts]

Ferm, you ever make it over to Kermit Weeks place in Lakeland, there are some great planes in there

[THEFERMANATOR]

Ferm, you ever make it over to Kermit Weeks place in Lakeland, there are some great planes in there

Nope, haven't made it to FANATSY OF FLIGHT yet. My grandfather has been several times though and knows many of the planes he has in there.

[THEFERMANATOR]

I made a couple of videos today of it and figured I would post over here. I'm playing with some hotter tunes, but still need to learn how to reduce the defueling some as it is slow to bring the power on.

http://www.youtube.com/watch?v=d6Taop8xnBo
http://www.youtube.com/watch?v=uFtvXp3dIws
http://www.youtube.com/watch?v=WrM_prRfqpY

[Skools Out]

i wanted to see burn outs :beer:

[macojoe]

Yea what he said!! anyone can hit the gas and drive away!!

[THEFERMANATOR]

i wanted to see burn outs :beer:

I'm having issues right now with the TCM commanding the ECM to reduce fuel on me for torque management. Until I can get an unlocked TCM from the tuner I'm sort of stuck with it like this. Plus 3.42 gears makes it a bit lazy off the line.

[THEFERMANATOR]

i wanted to see burn outs :beer:

As requested, I built up a tune without so much fueling delay and overided some of the torque management in the ECM and this is what I got.

http://www.youtube.com/watch?v=C6atnUMuwuE

[macojoe]

Now we are talking!!:news::clap:

[cterrebonne]

bad azz

[Skools Out]

now that's much better next we want a full burn out till she stops smoking them and your's flying lol no lifting throttle

[THEFERMANATOR]

I messed up on this one and left it in D, when it caught 3rd in lock-up it stopped spinning them and hooked up. It is some kind of fun though. I drove my DAKOTA today and it aint got NOTHING on my SUBURBAN., and not much could outrun my DAKOTA around here

[cterrebonne]

propane injection in the future?

[THEFERMANATOR]

propane injection in the future?

No, I'm stayin with straight diesel on this one. I built this up to get decent milage on trips and to tow anything I wanted to. I hadn't planned on it being as strong as it is when I built it up, I figured the 3.42's would have killed the power down pretty badly but as you can see it didn't hurt that bad.

[THEFERMANATOR]

I had to run in to TAMPA today for some parts and I got to do roughly 60% highway and 40% stop and go driving today and it averaged 19.5MPG. The highway driving was running 62-65, and I also got on it 3 times pretty good to pull out into traffic. Not too bad for milage considering my DAKOTA would be lucky to get 15-16 doing the same run, and it weighs in over a ton less.

[THEFERMANATOR]

Time for a long term update to this one.

Well I finally took the BURB on her first road trip this week. I sold a transfer case I had to a guy in North Carolina and the wife wanted to see snow. So we loaded up the BURB with clothes, us, transfer case, and the 2 dogs and headed north. All in all the trip went as smooth as could be other than now I have to go wash all the salt off and it's barely 40 degrees here. We traveled almost 1800 miles and I averaged 20.005 MPG for the whole trip. The milage really dropped off when the sun would go down and the air temps dropped as my EGT's would go up about 20-50 degrees at night and my boost would go up .5-1 pound as well. I figured I was getting close to 23 during the day driving, but at night it would drop off to about 18. Only needed the 4 wheel drive for a short stretch to get up to OBER GATLINBURG as she was fishtailing pretty bad going up those steep roads. I was also pleasantly surprised by how well she started in the cold. I wasnt able to plug in the block heater, but after sitting overnight it had warmed up to about 8 degrees at the motel we were at Friday Morning and she fired right up without hardly any smoke at all. Now I need to go clean her up, but heres a cold start video for you guys.

http://www.youtube.com/watch?v=7KybncEUsN0