NV4500 swap is underway

[MalibuSSwagon]

Larry, I am going to PM the pics of my pedal in a min, not sure if you determined that a hydro pedal is necessary or not at this point. I couldn't get great shots of under the dash anyhow.

I will keep a lookout at the local yards for you however.

[DirtyLarry]

Had a chance to sneak by an all-truck salvage yard about 40 minutes from my house this morning. Man, I think I just found my new favorite salvage yard! I have never seen more trucks for ripe pickin’s in one location in my life! I was like a kid in a candy store. Hard to believe this place is only 40 minutes from where I grew up and I never heard of it before. Actually, the yard is in my wife’s home town of Canon City but of course, she had no idea it existed.

Anyway, I scored a hydraulic clutch/brake pedal assembly from a 1989 chassis cab as well as the rod and other doodads that go between the brake hydrobooster and master cylinder that I needed. Then on my way out I found the NV4500 shifter stick that I really wanted…… A 1992-1994 shifter, as the knob matches the 73-87 tcase knob! Pretty happy about that. Got a bunch of other little things too.

Hydraulic pedal assembly on the left.




Check out this yard (terrible Blackberry pictures)...... this dude has more Squares than Home Depot! I haven’t seen this many square trucks in one spot since I was a kid in the 70’s/80’s drooling at the local GM dealer. He claims to have over 250 squares and 150 88 to ’09 trucks. I love this place!

Chassis cab that I pirated the pedals from….














Got a lot of work to do this weekend now that I have parts!

[Critter]

VERY NICE! Always fun to find a new honey-hole. I agree with you about the 92-93 nv4500 shifter, the ones like I have (95+) look like they came out of a space ship in my opinion. And while they look fine in the vehicle they came in they look out of place in an older model. Congrats on the parts score!

[edge]

What a yard (beds and tailgates!!!!). Nice pedal assy. Your set for now.

[Altec]

Dang. Any more of those mechanical pedal assemblies out there? How much did he charge for the complete tunnel?

[GCncsuHD]

Originally Posted by DirtyLarry

Should have nabbed that 73/74 grill. I should be picking one up today actually.

[jbclassix]

Hey that looks like Canyon TRuck!!! They used to have A LOT more trucks, but when scrap was over 300 per ton guess what. Can you believe they had more trucks!!!!!

[DirtyLarry]

Originally Posted by Altec

Dang. Any more of those mechanical pedal assemblies out there? How much did he charge for the complete tunnel?

Yeah, they had tons of mechanical linkage type clutch/brake pedal assemblies as well as at least 1 more hydraulic clutch/brake pedal assembly. About the only thing I could not find there was a front Dana 60.

I got out for $60 for a bunch of stuff. Pedals, back up light harness, shifter stick, tons of screws, bolts, clips, etc, hydroboost to m/c rod and a dome light bezel. It was hell carrying all of that stuff out as I have a broken foot and hobble around like an 80 year old man.

[DirtyLarry]

Originally Posted by jbclassix

Hey that looks like Canyon TRuck!!! They used to have A LOT more trucks, but when scrap was over 300 per ton guess what. Can you believe they had more trucks!!!!!

Yep, Cañon Truck. I would have loved to gone there when they had more trucks. I am a Pueblo native, aside from a 6 year hiatus in Detroit, and surprised I never heard of this place before. A buddy from a local salvage yard here told me about them. The guys at Cañon Truck were really friendly too whereas most of those type guys usually act like junkyard dogs.

[Altec]

Originally Posted by DirtyLarry

Yeah, they had tons of mechanical linkage type clutch/brake pedal assemblies as well as at least 1 more hydraulic clutch/brake pedal assembly. About the only thing I could not find there was a front Dana 60.

I got out for $60 for a bunch of stuff. Pedals, back up light harness, shifter stick, tons of screws, bolts, clips, etc, hydroboost to m/c rod and a dome light bezel. It was hell carrying all of that stuff out as I have a broken foot and hobble around like an 80 year old man.

Man, if I'm ever out there I'll have to make it a point NOT to stop there. I'll never have enough money to get home.

Hope the foot heals before you're done. Would suck to be done with it, and not be able to enjoy it.

[Dieselwrencher]

Very nice parts scores! Yards around here have very minimal trucks in them anymore due to scrap prices.

[jbclassix]

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

[snj8198]

I know where i'm going for vacation!

Do you still need that stick then Larry?

[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.

[snj8198]

DO I gota stand on my head to understand what im looking at?

[Rede]

Where or how are you getting the custom hoses made up?

I went to several places here, even a hydraulic hose company and they said "good luck with that..." =\

Only thing he could thinking of was using high pressure hose (1500psi) and some crimp style clamps but he didn't doubted that I'd be able to squish the ends of the hose enough for the clamps to prevent the hose from popping off the pump fittings.

[snj8198]

Check your local agriculture and heavy equipment implement shops. There are a few around my area that build high pressure hoses for logging equipment that have small diameter hoses and make crimps good for 5000psi+.

[Rede]

That's what this place specalizes in. lol

I brought the original lines in a told him that I'd like longer hoses made up with ends that match the originals.
He took one look and said "I don't have anything like those...

[Redcap]

Originally Posted by Rede

That's what this place specalizes in. lol

I brought the original lines in a told him that I'd like longer hoses made up with ends that match the originals.
He took one look and said "I don't have anything like those...

Sounds like a really crappy shop then...

[Rede]

Originally Posted by Redcap

Sounds like a really crappy shop then...

Yup. Just a regular mom and pop's place...have a look:

http://www.redl.com/profile/represent.html