HD 2wd/4wd new/old conversion

[SunSoaked]

I am seriously thinking about purchasing a 1st gen (2000-2006) HD Silverado with the LQ9 engine for a conversion project. I don't know much about these "newer" trucks, so i'm looking for pitfalls and knowledge of what I'm anticipating.

I don't think it matters if its 2wd or 4wd to begin with. As long as it has the vortec 6 liter and extended or 4-door option.

I want to take my newly rebuilt running gear I have and swap it in. I will be doing a Solid Axle Swap up front and converting it to a manual trans.

The new gear includes my dana 60, 14 bolt, nv4500, np205 and AA bellhousing adapter. Axles are from a 87 CUCV (4.56 w/lockers).

Mechanically, I thinks it's pretty much a bolt in deal using a SAS kit but, I expect issues with the computer not seeing an auto trans or shift button (if 4wd to begin with).

I appreciate any comments, feedback, advice and directions to useful info/sites.

Mike

[andrewmp6]

Look up the sas kits for that truck tho.Some trucks it matters if its 2wd or 4x4 to start some it don't.

[b454rat]

For one, don't waste your money on the AA kit. I'm pretty sure all you need to do is notch the housing for the shift rails to clear. Hope you have the right 205 as well. But you will need to swap the ECM for a manual trans truck, then it won't matter. The 205 has no electrics, and the ECM or truck doesn't care what t-case is there, cause it won't know it's there. Gonna havta figure something out for a VSS, check engine light will be on and no speedo. ORD can do the mods to get VSS on a 205. Search the net for SAS'd trucks, at least one or two has been done.

[SunSoaked]

Originally Posted by b454rat

For one, don't waste your money on the AA kit. I'm pretty sure all you need to do is notch the housing for the shift rails to clear. Hope you have the right 205 as well. But you will need to swap the ECM for a manual trans truck, then it won't matter. The 205 has no electrics, and the ECM or truck doesn't care what t-case is there, cause it won't know it's there. Gonna havta figure something out for a VSS, check engine light will be on and no speedo. ORD can do the mods to get VSS on a 205. Search the net for SAS'd trucks, at least one or two has been done.

So whats the "right" 205? Are you referring to a 205 with a VSS? I already have the AA kit; I assume it's needed to work with the passenger side diff for clutch linkage clearance?

[b454rat]

6 bolt round pattern 86 to 91. 91 being the unicorn of 205s. I've been junkyard'n for over 20 years, never found one. I actually only ever seen 2. But its not hard to make one, so no real big deal anymore. I think the AA kit is an adaptor to clear the linkage, I never looked at one so can't confirm. I know on pirate it's pretty much wasted money.

[obijuan]

Seems nobody knows that nwf makes a figure 8 to round adapter. No need to find a unicorn. Get a figure 8 32 spline 205 and notch and bolt up. Boom done.

[b454rat]

NWF makes good stuff. Not into the "hardcore" stuff anymore, since I can't even put brakes on my truck lol....

[SunSoaked]

Originally Posted by b454rat

6 bolt round pattern 86 to 91. 91 being the unicorn of 205s. I've been junkyard'n for over 20 years, never found one. I actually only ever seen 2. But its not hard to make one, so no real big deal anymore. I think the AA kit is an adaptor to clear the linkage, I never looked at one so can't confirm. I know on pirate it's pretty much wasted money.

I heard they were hard to find. Luckily I found a guy who sold me two brand new cases and guts from his supply of NOS. He only had 32 spline long inputs, so I ended up using the AA ring adapter to clear the rails.

Back to my original thought, I dont see why I cant bolt this 4500/205 unit into a 2005 era Silverado if I use a SAS kit along with my Dana 60?

[b454rat]

No reason you can't. I believe they still came with the 4500, and would just need to mount the 205, which shouldn't be difficult. Sky Man. makes an affordable SAS kit, but I'd search around and whats out there. I'm not up on these trucks to know what works and what doesn't. But it makes me want to SAS my truck....

['63GENIII]

What are your thoughts on shifting the 205? Single stick? Twin stick? Cable or linkage?

I think its totally possible under a CC. A lot of real estate to work with.

For the PCM not seeing the auto trans - you can have the automatic programmed out and the manual trans programmed into it. Just leave the auto wire harness secured to the frame and out of the way. Only thing you will need is the correct vss from the rear of the auto and the right plug. There are 2 for the 4l80E. The front is for input speed and the rear is for the speedometer and I'm pretty sure it will be what the PCM uses when you get rid of the auto tune.

You might have to do a little dissecting of the auto's wire harness to find the reverse lights as well.