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Welcome to the 3500HD.com forum created October 2009

Author Topic: another newb with 3500HD  (Read 1790 times)

jim in n.y.

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another newb with 3500HD
« on: July 14, 2016, 02:25:15 PM »
Hi everyone,
    Just thought I'd introduce myself. My name is Jim and I live in Upstate N.Y. near Saratoga Springs. I just picked up a '97 bare cab and chassis ( 68k miles) with no motor or trans. Was a 6.5l turbo and 4L80E. The plan is to drop in a 6.2L with turbo and a Clark 280VO 5 spd overdrive I have kicking around here just to get it running/driving. I can't believe how rust free this truck is for having spent it's life in the northeast! This is a long term project as I'm currently doing a 6.2L turbo conversion on an '88 K5 . Was 5.7L TBI  with 38k miles. I'm not new to diesel conversions as my usual summer driver is an '84 stepside with a 3-53T and Spicer O/D trans.
  I'm not a real big fan of the '88-'99 body style. I bought this for the chassis to build as a hauler. I eventually want to put a rust free '84 crew cab I have on the HD chassis with an aluminum 6V-53T and an aluminum flatbed .Not sure yet on what trans I'll run, maybe an Allison 2000 6 spd. Other than the obvious frame stretch and new cab to frame mounts does anyone out there see any serious issues? Like wheel well opening clearance or something else serious? Also feel free to comment on what you think a  square nose crew cab on the HD chassis would look like. I hope the picture posts ok.
      Thanks, Jim.
 
'84 chevy stepside , Detroit 3-53T w/Jakes, spicer 3853-B 5 spd. with O/D. 3.08's
'88 K5 Blazer ,350 TBI ,700R4,3.73's soon to be 6.2L Turbo
'84 crew cab dually 2wd ,350,SM465 w/4.10's
'97 3500HD was 6.5L w/4L80 & 4.63's hope to have 6V-53T w/Allison 2000

Raymo

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Re: another newb with 3500HD
« Reply #1 on: July 14, 2016, 04:48:01 PM »
Seems like you're crazy enough to fit in, so welcome!

I'm at the tail end of a 6-speed 1000 swap in my Cummins powered HD, so I'm excited to see the 6v/2000 set up!
'94 3500-HD, Cummins, Getrag, NP205. Shortend rear frame with a Pickup Bed. Dana 60 front, stock 80 rear.

'03 2500-HD 8.1 and Allison

ED-NY

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Re: another newb with 3500HD
« Reply #2 on: July 14, 2016, 04:52:30 PM »
Jim

Welcome to the forum..I'm a couple hours north of you right off I-87 in Champlain.  Not sure about the body mounting but I like the 88-98 body style ;)

Hopefully someone will jump in with some answers. Just finished a 135.5 WB cab/chassis project after about 4 years of collecting parts.

Ed

jim in n.y.

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Re: another newb with 3500HD
« Reply #3 on: July 14, 2016, 11:47:13 PM »
Thanks everyone!
    Ed, it's nice to know there is someone close by . I'm just off exit 16 of I-87. Hopefully the pictures will come through this time. Although she's not much to look at. Just your average 3500HD. The only option was A/C. I decoded the vin and RPO codes. No surprises.
Raymo, If I go with an Ally I'll probably be hitting you up with lots of questions. I know I would need a stand alone TCM . I'm told to go with GM and not aftermarket.
    A question about the front grille. I see some guys have swapped in a GMC quad headlight setup . I think they are called a sport grille? Was this an option? Is it just plug and play or are there any mods needed? They look a lot cooler than the original.
          Jim
'84 chevy stepside , Detroit 3-53T w/Jakes, spicer 3853-B 5 spd. with O/D. 3.08's
'88 K5 Blazer ,350 TBI ,700R4,3.73's soon to be 6.2L Turbo
'84 crew cab dually 2wd ,350,SM465 w/4.10's
'97 3500HD was 6.5L w/4L80 & 4.63's hope to have 6V-53T w/Allison 2000

someotherguy

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Re: another newb with 3500HD
« Reply #4 on: July 15, 2016, 08:45:21 AM »
Welcome Jim,

I don't see any issue with putting a square cab on there; you'll just probably need to position it "high enough" like the 88-98 cab for clearance.  It's got sort of a built-in body lift of about 3" when compared to a lighter duty 88-98.

The grille swap is dead easy.  It's not exactly plug-and-play but very close.  The headlight wiring is different but that's easy to fix.  The composite style headlights bolt right up as does the grille, which you'll need from a 94-up model for one that is a direct fit.  You'll also need the park light housings from 94-up, and the corner lenses from 94-up and whichever make you go with Chevy or GMC as the corner lenses differ enough to not swap.

Headlight wiring you can easily handle as it's just breaking out the sockets to a pair and the correct 9005/9006 bulb style connectors.  Or you could get the lamp harness section from a properly-equipped truck; the year would have to be...oh...I want to say 95-97 or possibly 96-97.  The 94-older don't have the correct end where it joins the rest of the harness, and they changed it again in 98.

Richard
06 Silverado ISS / 06 Silverado SS / 06 300C SRT8

ED-NY

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Re: another newb with 3500HD
« Reply #5 on: July 16, 2016, 12:05:06 PM »
All the talk about headlights...I have a harness probably from a 1998 (K1500) with dual headlamps...sent it to a guy years ago and the USPS couldn't deliver it for some reason....so it's back in my barn

jim in n.y.

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Re: another newb with 3500HD
« Reply #6 on: July 17, 2016, 06:15:19 PM »
Everyone,
     Thanks for the reply. Sorry for not getting back sooner. I work 12 hr. night shifts and don't always have access to a computer. Probably not going to do much work to this truck right now as I have more important irons in the fire. Probably just start gathering some parts for now. I was going to put a Clark 280 O/D behind the J code 6.2 as that has a park brake on it and O/D but I have a line on a TH400 with park brake so it might be easier to install as the truck was originally an auto. I have a Mitchell (the big suitcase sized one) aux. transmission that I can use for O/D. Keep in mind these are all just quick fixes to get it running/driving. I don't want to spend a lot of money on it just to tear it all apart to do the Detroit / crew cab conversion later.
     I'll try and post some more pics of all the junk I'm talking about.
                        Jim
'84 chevy stepside , Detroit 3-53T w/Jakes, spicer 3853-B 5 spd. with O/D. 3.08's
'88 K5 Blazer ,350 TBI ,700R4,3.73's soon to be 6.2L Turbo
'84 crew cab dually 2wd ,350,SM465 w/4.10's
'97 3500HD was 6.5L w/4L80 & 4.63's hope to have 6V-53T w/Allison 2000

jim in n.y.

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Re: another newb with 3500HD
« Reply #7 on: July 17, 2016, 06:31:04 PM »
A couple of more questions,
      The hydraboost master cyl. and accumulator assy. are missing. Does anyone know if an older square body unit would fit? I have a ton of those kicking around. Also, when I do the 6V conversion I'm pretty sure the accumulator will be in the way. I've made adapter plates so you could re-clock them but that was for the square body ones. Do you see any reason I couldn't do it on the HD? Maybe even use one from a step van as those were mounted 90 degrees to the firewall with a special bracket?
  And lastly, The engine/transmission computer was missing. Do I need one to control any of the other functions (besides engine and trans) like dash controls or gages?
                    Jim
'84 chevy stepside , Detroit 3-53T w/Jakes, spicer 3853-B 5 spd. with O/D. 3.08's
'88 K5 Blazer ,350 TBI ,700R4,3.73's soon to be 6.2L Turbo
'84 crew cab dually 2wd ,350,SM465 w/4.10's
'97 3500HD was 6.5L w/4L80 & 4.63's hope to have 6V-53T w/Allison 2000

fabman72

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Re: another newb with 3500HD
« Reply #8 on: July 17, 2016, 07:02:49 PM »
Ed ,what would you have to have for the harness i am needing one hear soon.

ED-NY

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Re: another newb with 3500HD
« Reply #9 on: July 17, 2016, 07:32:55 PM »
Ed ,what would you have to have for the harness i am needing one hear soon.

$25 plus postage OK?

ED-NY

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Re: another newb with 3500HD
« Reply #10 on: July 17, 2016, 07:43:31 PM »
A couple of more questions,
      The hydraboost master cyl. and accumulator assy. are missing. Does anyone know if an older square body unit would fit? I have a ton of those kicking around. Also, when I do the 6V conversion I'm pretty sure the accumulator will be in the way. I've made adapter plates so you could re-clock them but that was for the square body ones. Do you see any reason I couldn't do it on the HD? Maybe even use one from a step van as those were mounted 90 degrees to the firewall with a special bracket?
  And lastly, The engine/transmission computer was missing. Do I need one to control any of the other functions (besides engine and trans) like dash controls or gages?
                    Jim

I'm not sure but I have a couple 88-98 units laying around...but they should be very common down your way.  I just removed one from a 2002 Chevy 3500 I parted out and will compare it with an 88-98 unit.

One thing I see discussed is that you need to use the brake pedal from the hydro-boost donor? I recently converted a 94 vacuum cab to hydro-boost and used the K2500 pedal in it and it works fine. ;)

Do yourself a (big) favor (I didn't)...while the hydro-boost is on your work bench change the piston seal...here's a thread discussing the procedure:

http://3500hd.com/index.php?topic=1143.0


I installed a 350 TPI engine in mine and re-pinned the K2500 ECM to use the TPI 730 ecm...you won't need the ecm for the dash lights etc...but it is used for the check engine lights etc. Been messing around with flashing the OBD1 ecm's, I have all dash gauges, ALDL connector and MIL indicator working .
« Last Edit: July 17, 2016, 07:52:14 PM by ED-NY »

jim in n.y.

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Re: another newb with 3500HD
« Reply #11 on: July 17, 2016, 09:33:07 PM »
Ed,
   I'll use the existing brake pedal that's in the HD now, so it sounds like I should be ok there. On the square bodies that I messed with the pedal was good to go as is but converting from Vac to Hydra I needed to use the pushrod ( longer) from the Hydra. I also needed to make an extension for the pushrod because when I re-clocked the accumulator I needed to make an adapter plate that went between the master cyl. and the accumulator assy. I can't quite remember what I did exactly on the firewall end of the accumulator when you re-clock it. I do remember having to machine a special deep well socket to fit the large nut that fastens it to the firewall plate. I also think the threads on the accumulator had a dead spline that indexed it to a tab in the firewall plate and I just removed the tab. So if anyone needs to re-clock thier accumulator to get it out of the way for some reason , there is a way.
         Thanks for the tip on replacing the piston seal !
  Since I'll be installing a mechanical 6.2 and trans. it sounds like I'll be good to go without the ECM.
        BTW, what's an MIL indicator?
'84 chevy stepside , Detroit 3-53T w/Jakes, spicer 3853-B 5 spd. with O/D. 3.08's
'88 K5 Blazer ,350 TBI ,700R4,3.73's soon to be 6.2L Turbo
'84 crew cab dually 2wd ,350,SM465 w/4.10's
'97 3500HD was 6.5L w/4L80 & 4.63's hope to have 6V-53T w/Allison 2000

ED-NY

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Re: another newb with 3500HD
« Reply #12 on: July 17, 2016, 10:45:42 PM »
 
        BTW, what's an MIL indicator?

Malfunction Indicator Light (Check Engine Light) :)

 


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