Project "Man Pedal"
 

I figured I'd start a project thread for my manual tranny swap in my 86 K5. I'll get some pics this weekend. I believe I have all the parts collected to begin. Once I sell the 700r4/208 combo I will drop them.

I originally found a 1971 SM465/NP205 combo and bought the pedals and bell housing/hydro clutch from board members. Going to use them but I found another SM465/NP205 combo from an 1984 and will use them vice the 71 parts. I will be able to use my front driveshaft from the 700R4/208 but will need to fabricate one for the rear.

I am hoping to find some 8-lug axles(3/4 ton) before this is done so I can swap them in too.

Other plans:
-Raptor line the inside (interior is removed)
-new exhaust with ram horns purchased from a board member (currently has headers that prevent installing front drive shaft)
-has a small amount of lift via add-a-leafs front and rear (might replace with lift springs)

Re: Project "Man Pedal"
 

My first update, sold the 700r4/208 combo. Dropping them this Saturday. Then I'll start putting her back together.

Re: Project "Man Pedal"
 

Got the headers off today. Tranny/TC will be gone tomorrow.

Re: Project "Man Pedal"
 

700r4 and np208 removed.

Re: Project "Man Pedal"
 

1971 SM465 and NP205 I was going to use. The 1984 SM465 is in the background as is the 1987 bell housing I am going to use.

Re: Project "Man Pedal"
 

The 1984 SM465 and 1984 NP205. Tomorrow I am going to remove the old pedal assembly and mark the firewall to mount the master cylinder and reservoir. I also need to look into cross members, not sure if the auto cross member will work, looks like it does not drop down in the center far enough.

Re: Project "Man Pedal"
 

Your cross member may work I swapped a 68 465 into my 77 and it worked so I suppose it should.

Re: Project "Man Pedal"
 

I have the 71's cross member, I will try it too.

Re: Project "Man Pedal"
 

Looks like I need a pre 85 cross member to work with my 84 SM465/NP205. The nice thing is I found one locally on craigslist. Going to get it tomorrow!

Re: Project "Man Pedal"
 

I went to pick-up the cross member I found and come to find out the truck he was parting out was an 86, not an 84. Oh well, still looking for a pre 85 cross member.

Re: Project "Man Pedal"
 

Looks like you're making good progress. I must say I'm a little surprised to see you swapping an overdrive trans with a non-overdrive unit. What motivated the auto to manual swap?

Re: Project "Man Pedal"
 

I have always enjoyed driving the manual trannys. This vehicle is more for fun, I have a Tahoe I drive for day to day stuff.

No update, but I have everything I need to install the 465/205 into my K5. Might be another week since the clutch went out in my K25 and I want to get it back on the road first.

Re: Project "Man Pedal"
 

Well. My K25 clutch issue was not the clutch. Turns out the power sleeve splines were all stripped out. Ordered a new one on ebay. Also, the last few odd and ends are coming in, tranny hump and shifter for the K5. Probably replace the power sleeve in that one too.

Re: Project "Man Pedal"
 

Lots of progress today. The tranny is in! Also, have the adapter bolted to the transmission and the cross member installed. No more jack-stand holding up the engine!

Going to swap pedal assemblies and install the clutch master cylinder tomorrow. The slave cylinder needs to be replaced or rebuilt too.

Also going to install the ramhorns and looks like a custom dual exhaust or maybe a heartthrob exhaust. Not sure yet.

Re: Project "Man Pedal"
 

Started to remove the pedal assembly and drill the holes. Also mounted my "new" exhaust manifolds. You can see the dimples on the firewall next to the brake booster where the clutch master cylinder mounts.

Re: Project "Man Pedal"
 

manifolds and tranny installed:

Re: Project "Man Pedal"
 

Started prepping for pedals.

Re: Project "Man Pedal"
 

Couple more.

Re: Project "Man Pedal"
 

Got the steering column out of the way. Easier than I thought. Also, started putting the pedal assembly in. Here's a couple update pics.

Re: Project "Man Pedal"
 

I got the steering column in.

Re: Project "Man Pedal"
 

Nice progress! Real men drive stick!

Re: Project "Man Pedal"
 

Thanks Jason. Before I put the gauges back in I need to make sure I have the clutch pedal attached to the master cylinder correctly. Looking for some pics/info now.

Re: Project "Man Pedal"
 

Quick update. I should be all done by March 1st. I have ordered an exhaust kit and the drive shafts are at the driveline shop now. Worked out my clutch hook-up issue and the interior is almost all back together.

Re: Project "Man Pedal"
 

Awesome! You must be excited to drive it.

Re: Project "Man Pedal"
 

I am, this has been 2 months longer than I planned.

Re: Project "Man Pedal"
 

Almost done. Drive shafts are in. clutch hydraulics all hooked up. All that's left is the exhaust, I need a dry day to get it installed. Once I drive it and everything checks out I will put the instrument cluster in and the tranny hump. So close. ....

Re: Project "Man Pedal"
 

She moved under her own power today! Just over 4 montHs off the road. Ran good, but the 4 month old gas needs to be drained. I plan on buttoning up the interior this weekend.

Re: Project "Man Pedal"
 

Awesome! How is the new clutch working out for you?

Re: Project "Man Pedal"
 

Works good, I had to bench bleed it. Nice and smooth, I like it better than the mechanical linkage.

Re: Project "Man Pedal"
 

I had a set back, seems the input shaft bearing was bad and gave up the ghost. So, I decided to find another tranny and swap it in. I picked one up with bell housing and shifter for $200 last weekend. Me and my sons got it installed today, took about 4 hours. Works great, put about 30 miles on it. Now I have another side project some day, rebuild the SM465. But first I need to finish the interior.

Re: Project "Man Pedal"
 

I bet it feels good to be driving it around again.

Re: Project "Man Pedal"
 

It does Jason. Now I am going to freshen up 2 10-bolt axles I bought with lower gears and slide those under the K5.

Re: Project "Man Pedal"
 

Been awhile for an update. Bought some cucv axles a month ago and the dana 60 front is under the blazer. Once I get the perches moved the 14 bolt will make it under the rear. I need to hook up the drag link and brake lines and the front is ready to roll. I will get some pics tomorrow.

Re: Project "Man Pedal"
 

Ordered new perches, u-bolts and top plates from ORD as well as brake lines. Going to get the old perches off this weekend and replace the rear brakes and an axle seal. this way I will be ready to bolt her in after the perches cool.

Re: Project "Man Pedal"
 

Work is progressing, bought a plasma cutter and some 4" front and rear leaf springs. I hope to hit this hard this weekend, the wife will be at work and looks like some decent weather.

Re: Project "Man Pedal"
 

Nice build, I also love the manual trans, have one in all three of my pickups,wife has the automatic, we need pics!

Re: Project "Man Pedal"
 

I will take some this weekend. I also found a cab for my son's M1031, the 6.2 runs strong just need to swap cabs. The nice thing is the cab has a manual steering column and is an 86 too. That will clean up the K5 interior. Going to add that to the list of things to do.

Re: Project "Man Pedal"
 

Scored an 86 cab with manual, tilt steering column with a nice GMC steering wheel. Going to put it in the K5. I also took the pedals/hydro boost set-up off too. I might sell them, not sure at the moment. Pics to follow.

Re: Project "Man Pedal"
 

Here's the dana 60 installed and the 14 bolt with perches removed and the 4" lift springs next to it.

Re: Project "Man Pedal"
 

Made lots of progress. Got the 14 bolt under the rear w/ the wrong 4" lift springs. (bought 56" springs vice 52" springs, guy didn't know what he had) Put the 4" lift springs in the front. Things left to do:

Hook up new brake hoses front and rear and new front calipers
New front driveshaft
Install new to me manual tilt steering column
Install steering correction (probably a 3" block on the Dana 60, not ready for crossover)
Replace wrong rear springs