NV4500 swap is underway

[jbclassix]

you said you had to carry all the stuff out, are you not allowed to drive in anymore?

[DirtyLarry]

Originally Posted by jbclassix

you said you had to carry all the stuff out, are you not allowed to drive in anymore?

Not sure, I didn't ask and they didn't offer. Although, they did give me a lift down to the squares in an old beat up G-van.

[DirtyLarry]

It doesn’t look like it, but my buddy and I got a lot done Saturday. He tackled the rust in the floorboard and I went after retrofitting the clutch master cylinder, which turned out to be an all day event. Got the clutch m/c and hydrobooster mounted, installed the pedal assembly and reinstalled the steering column. Also tied up and rerouted several wires under the dash.

Made a template from the donor truck at the junk yard. It was easier to follow the template from inside the truck


After the firewall, pedals, and steering column was put back together. The clutch m/c almost looks factory! Pretty slick the way the GM engineers had the clutch m/c mounting studs connected to the clutch/brake pedal assembly via 2 rods. It will sure be nice to have a straight clutch pedal again too! The old one was so badly bent, I often hit the dimmer switch when stepping on the clutch.


The brake master cylinder won’t be here until Tuesday. All of the wires going into the cab that run the dual battery isolator, fuel transfer pump, etc have been wrapped with vacuum hose. I prefer to use vacuum hose to protect single wires more than split loom when possible.


Bill cut out the rusty floor board and cab support brace. The truck doesn’t have an ounce of rust on the body but the floor board corners and front cab supports were in need of attention. The floor will be sprayed with Rhino once complete.


Once the rust repair is complete next weekend we'll start stabing the trans/tcase and modify the crossmembers. Until then I am going to start installing the ZF P/S pump this week and get ready to have the medium duty truck P/S lines I purchased from work tweeked to fit the Saginaw steering gear. Wait until you see the size of the P/S reservoir I got! Don't know where in the hell I am going to mount it but it will be awesome, especially when ever I get a hydraulic winch!

[Rede]

I'm just stumbling onto this build now so I appologize if its mentioned in another thread, but...

What are you doing for a ps pump and lines to the steering box?

I have a gen6 454 in my engine bay which has the hydraboost pump, but I'm stumped at how to plumb it to my steering box. (my truck is an 82 K20)
I might just end up going to a 1/2 ton vortec ps pump instead just to keep it simple as I don't have anything else from the hydraboost setup.

Sorry for the hijack.

[DirtyLarry]

Originally Posted by Rede

I'm just stumbling onto this build now so I appologize if its mentioned in another thread, but...

What are you doing for a ps pump and lines to the steering box?

I have a gen6 454 in my engine bay which has the hydraboost pump, but I'm stumped at how to plumb it to my steering box. (my truck is an 82 K20)
I might just end up going to a 1/2 ton vortec ps pump instead just to keep it simple as I don't have anything else from the hydraboost setup.

Sorry for the hijack.

I am using a late model medium duty truck P/S pump and lines. Although the lines will need to be modified to fit the old Saginaw steering gear. Pictures of the pump are on the first page of this thread.

From what I can tell your hydroboost pump just has two return ports. Plug one off and you should be fine.

[duallyjams]

Originally Posted by DirtyLarry

I am using a late model medium duty truck P/S pump and lines. Although the lines will need to be modified to fit the old Saginaw steering gear. Pictures of the pump are on the first page of this thread.

From what I can tell your hydroboost pump just has two return ports. Plug one off and you should be fine.

GM 1ton step vans have hydro boost and use a factory t in the return line to the pump verse having 2 returns ports on the pump. FIY

[DirtyLarry]

Originally Posted by duallyjams

GM 1ton step vans have hydro boost and use a factory t in the return line to the pump verse having 2 returns ports on the pump. FIY

Yep…. in fact, that is what I am using is the modern P-chassis, which is now a Navistar product called Workhorse. That is the company I work for.

I could have kept the original P/S pump that is on the 8.1L now but I wanted the ZF pump for its durability, especially once I get a hydraulic winch. Since this truck is in pieces anyway, now was as good as time as any to throw it on.

Here is an engineering layout of our lines for a 2010 Workhorse 14,500 GVWR stepvan chassis with a L96 Vortec 6.0L and ZF P/S Pump and ZF P/S gear. The ZF pump only has a pressure and return port with a T in the return side. I am planning to use this exact P/S cooler and as much as these lines that I can but using a P/S reservoir from a larger vehicle for added capacity....If I can make it fit. These lines will need to be modified where they screw into the original K10 Saginaw steering gear. One of these lines may come up short as the engine sits closer to the firewall in a stepvan chassis than on a pickup.