American Heart Transplant: FJ60 + Vortec

[dbleon]

Just starting a build thread here because I want to document the process and I'm sure I'll need alot of help along the way.

The plan:

General idea so far (very general...)

5.3l complete legal swap
4l60e + Advanced Adapters to stock split case
Howell harness or ?
motor mounts AA or custom
x-member AA or custom
Aftermarket radiator/tranny cooler
Custom PS and AC lines
All aftermarket gauges on custom dash panel
Havent started thinking about small stuff just yet

I have finally gotten the ball rolling on this project. I have been tearing things off the truck, and just today aquired a fully dressed 5.3 and 4l60e for a screaming deal locally!

2004 5.3l gmc sierra 53,144 miles and 4l60e (4x4 version).

Complete from head to toe (need gas pedal and TAK)

Couple questions before I get to the pictures.

1) Are there any alternative to AA split case adapter?
2) Tranny is 4x4. I was told i can swap tailhousing to 2wd to use AA's adapter. Is this true?
3) I want to use rubber motor mount style, but have heard of strength issues. Any other options?
4) What is the key in the mounting location? Is it to get drivelines straight? Do I want it perfectly center in the frame rails?
5) Will the stock exhaust manifolds fit? If not, what other options have proven to work?
6) I have a billion questions I'm sure... but anything you guys would have concerns on parts wise?

Transplantee prepped for surgery!

Donor Heart!

More to come hopefully soon!

 

[Journey]

I'm getting ready to start the same thing. I will be keeping an eye on this post. ON the FAQ page there is a very detailed swap: https://forum.ih8mud.com/60-series-wagons/174821-another-cruiser-gets-vortec.html
you should check it out

 

[OyajiJon]

It's a long road, but the fun that lies at the other end is, well, FUN! I'm glad you found a good deal on the drive train.

Good luck!

 

[Kurtis]

I think the other alternative besides the aa adapter would be to run a chevy rear axle and a chevy transfer case.
I did it with the aa adapter but if I had to do it again I would lean towards a gm transfer and axle. More choices for disk brakes, lockers, and gearing. Plus it would probably cost less than the aa adapter and all the upgrades are a lot cheaper.

 

[topaw84]

If you have the original harness send it to wait4meperformance. Jesse does a great job and it saves quite a bit of money. They did mine got it back in two weeks. They mark everything very well and it's pretty straightforward.

Go with a custom cross member, aa's doesn't seem to work on most rigs.

Placement is all about measuring. Measure DL angles before you pull everything and try to mirror those with the swap.

Also you'll need to decide on oil pan options. The stock will work but will need fabbing.

 

[satchel]

Did the throttle pedal come with the engine or are you swapping over to a cable actuated throttle body?

 

[dbleon]

If you have the original harness send it to wait4meperformance. Jesse does a great job and it saves quite a bit of money. They did mine got it back in two weeks. They mark everything very well and it's pretty straightforward.

Go with a custom cross member, aa's doesn't seem to work on most rigs.

Placement is all about measuring. Measure DL angles before you pull everything and try to mirror those with the swap.

Also you'll need to decide on oil pan options. The stock will work but will need fabbing.

I have the original. How much did he charge ya for the harness? Does it basically plug and play? Oil pan.. thinking of going to the ls1 style as I need a new pickup tube too (bent).

Did the throttle pedal come with the engine or are you swapping over to a cable actuated throttle body?

No, gas pedal not included. Im going to stay DBW. Need to get a pedal and TAK at junkyard.

What are people running for tranny mounts? I was thinking custom crossmember with rubber pucks...

 

[OyajiJon]

Also you'll need to decide on oil pan options. The stock will work but will need fabbing.

This is a great point that I forgot about from the days collecting the parts for the 5.3 swap in my stolen FJ40. I think I still have the GM invoice for the parts I ordered to fit the Camaro oil pan if you want me to send the numbers your way.

 

[MANUCHAO]

if yah got a welder and or a buddy with with a welder fab your own motor mounts and X-member...
Get your TAC from any 2004 to 2007 will work.. Pedal is a different story.. I think I used one from a 2005.
Get your oil pan swapped before you install that engine.
If you can go with headers do so.. if not corvette or GTO exhaust manifolds will work..
Engine placement goes like this.
Line up your drive lines, check check check your hood clearance, engine offset to driver side but watch out for that steering gear box.
Also, set your drivetrain making sure your front drive shaft will clear the tranny oil pan.. it should by all accounts..
Howell does good work I have heard (wish I would of used them) but sounds like you got a good lead already..
Customer service makes a HUGE difference when dealing with harness and ECU re-flash...
I would say stay with the AA for the TC as you will want this swap to go nice and steady.
A bit late but I would of suggested getting ALL (if not most of your parts) before starting the tear down..
Waiting on parts sucks.....

Good luck and keep at it......

 

[dbleon]

This is a great point that I forgot about from the days collecting the parts for the 5.3 swap in my stolen FJ40. I think I still have the GM invoice for the parts I ordered to fit the Camaro oil pan if you want me to send the numbers your way.

Is the camaro pan nessesary, or just make things easier? If you could pm me the list that would be shweet!

if yah got a welder and or a buddy with with a welder fab your own motor mounts and X-member...
Get your TAC from any 2004 to 2007 will work.. Pedal is a different story.. I think I used one from a 2005.
Get your oil pan swapped before you install that engine.
If you can go with headers do so.. if not corvette or GTO exhaust manifolds will work..
Engine placement goes like this.
Line up your drive lines, check check check your hood clearance, engine offset to driver side but watch out for that steering gear box.
Also, set your drivetrain making sure your front drive shaft will clear the tranny oil pan.. it should by all accounts..
Howell does good work I have heard (wish I would of used them) but sounds like you got a good lead already..
Customer service makes a HUGE difference when dealing with harness and ECU re-flash...
I would say stay with the AA for the TC as you will want this swap to go nice and steady.
A bit late but I would of suggested getting ALL (if not most of your parts) before starting the tear down..
Waiting on parts sucks.....

Good luck and keep at it......

Tore down and selling/sold many parts to make this happen. Truck is not a daily driver (yet), so I have no timeframe.

Next steps:
1) pulling the old beast out.
2) buy AA parts
3) lots of clean up on vehicle
4) Swap output shaft on tranny
The list goes on.

Is 220v welder nessesary on the motor mounts to frame?

I want to do small patch reinforcements on frame (1/4" plate) before mounts are burned in. Will this throw the geometry off if using AA mounts?

Thanks guys!

 

[MANUCHAO]

Good deal on it not being a DD yet...
Dont know about the 220 being needed but that's what I have and used.
If you going to weld plates make sure they are the same thickness as the frame and as tall as the frame.. it will make welding a lot easier.. and cut them in an oval or diamond shape..... it wont throw the engine placement down.. you got lots of space in there...

 

[topaw84]

Wait4meperformance charged me $330 shipped. It's pretty much plug and play. You'll need a few relays and a fuse block. Also get them to pull the three wires for cruise control if want to hook it up later or during the install.

Stick with the mechanical fan. I did and haven't had a overheating issue yet.

 

[dbleon]

Good deal on it not being a DD yet...
Dont know about the 220 being needed but that's what I have and used.
If you going to weld plates make sure they are the same thickness as the frame and as tall as the frame.. it will make welding a lot easier.. and cut them in an oval or diamond shape..... it wont throw the engine placement down.. you got lots of space in there...

Sweet. Hopefully I can find someone local to do the fab work that wont charge me an arm-anda-leg. Bad idea to learn to weld on motor mounts? I was thinking of buying a 220 welder and trying to do this ish myself...

Wait4meperformance charged me $330 shipped. It's pretty much plug and play. You'll need a few relays and a fuse block. Also get them to pull the three wires for cruise control if want to hook it up later or during the install.

Stick with the mechanical fan. I did and haven't had a overheating issue yet.

Plan is mechincal fan with fiberglass shroud. I'm really good with fiberglass so shouldn't be a problem.

Starting to consider chevie x-case and axle setup. Seems cheaper, whats the problem? I want to go SOA too... so it seems logical.

 

[dbleon]

Just got off the phone with Advanced Adapters... The tech told me thier kit is universal for 2wd or 4wd 4l60e. But on thier site is says for exclusive use with 97+ 2wd 4l60e. Am I missing something. The tech told me the spud shaft is included and you just swap that out in the transmission.

Can anyone confirm that the AA kit works on a 4wd 4l60e?

D

 

[Clonestocker]

dbleon,
I'm down in Tucson and getting ready to start my swap. 1997 Vortec/4L60E out of a 2wd truck. See Photos. I was told if you get a 2wd trans you just have to shorten the shaft. There is also two adaptors. One holds the VSS. I don't know what to do about the harness either. Howell, the person in your post (haven't heard about this one) also the It's Alive thread sounds like he did his own. I'll be doing all my own fab work. Also heard of a way possibly to use the stock cross member. Have you shopped for an adaptor yet? I got a smoking price from the Hot Rod shop down here. We need to stay in contact. matt

 

[satchel]

I'm not so sure the 4wd tranny will work with the adapter. You do have to shorten the output shaft of the 2wd tranny but I think the 4wd shaft is not long enough. And you don't change the output shaft of the tranny with the spud shaft like the guy you talked to said, the spud shaft slides onto the output shaft. I would suggest calling AA back and talking to someone else.

 

[dbleon]

I'm not so sure the 4wd tranny will work with the adapter. You do have to shorten the output shaft of the 2wd tranny but I think the 4wd shaft is not long enough. And you don't change the output shaft of the tranny with the spud shaft like the guy you talked to said, the spud shaft slides onto the output shaft. I would suggest calling AA back and talking to someone else.

He told me the shaft is included and works for either transmission. I'll call back before ordering... he was very short and kind of rude with me.

 

[satchel]

Well to put it plainly the output shaft has to be cut to an exact measurement before the spud shaft is put on or the adapter won't fit. I can see if I can find what that measurement is and you can see if your output shaft is long enough but if it isn't there is nothing in the AA kit to replace that shaft.

 

[dbleon]

Well to put it plainly the output shaft has to be cut to an exact measurement before the spud shaft is put on or the adapter won't fit. I can see if I can find what that measurement is and you can see if your output shaft is long enough but if it isn't there is nothing in the AA kit to replace that shaft.

5.5" from the housing correct? I read through thier instructions once. I guess I'm confused.

Here is a picture of the transmission. I would have to remove the tailshaft housing circled correct?

 

[satchel]

I don't think you are reading the instructions correctly, or you are looking at ones that I haven't seen or they are for another kit or something. My kit says that the output shaft must be cut to 5.5 inches from the first adapter spacer or whatever it is called. Basically, you take the tailhousing off like you show, then put on their piece, then measure 5.5 inches from that. Read here: http://www.advanceadapters.com/downloads/50-0408A.pdf Specifically the red text on page 3.