I know there are several of these around but I'd thought I'd post some of my progress with mine so far. My build is more or less budget oriented and I still have a few things left to do. So far I will post a summary on where I stand currently.
So far if I'm being honest the hardest part of the swap is installing the clutch pedal, I thought it was overrated when reading other builds, but they are right its a pita, and it took me several days to figure a way to get it installed the way I wanted it, with a clean hole and OEM finish. after the clutch and master cylinder was installed everything else was straight forward.
2nd hardest thing was removing the 4l60E, I had a fight with the Torque converter bolts and it took me longer than what I would like to admit.
After the auto was out everything else took me a day to install and fill with fluid. "back breaking"
I know some of you wonder why I went with the 3500 instead of the 4500 but I prefer the gearing over the 4500 despite the 4500 being a hell of a lot stronger, and heavier. Which was my main consideration. I did all the work mentioned above in my back in the driveway so, a 200 pound 4500 by my self wasn't a smart idea and I prefer the gearing and snappy shifting of the 3500, I could have gone t56 but I would have lost 4wd which I wasn't willing to do, and these things cant be had for less than $2k. This will be a daily driver/fun truck so I don't need the extra beef of the 4500 and I wont be towing either. 4500 is the same process as the 3500 just add another 100 lbs of pain.
Things still left to do:
Wire the reverse lights
Wire clutch switch so it doesn't start in gear without the clutch being depressed "safety" not that I need it but I want an OEM finish because I will be teaching the kids how to drive a manual, "RIP clutch."
Cut and balance front drive shaft "I'm using a manual 241c Tcase from the 90s only had 55k miles, but I still rebuilt with new bearings/bushing/fork pads,pump,chain, and seals."
Wire Tcase to front diff, I just need to buy some wire and solder so it engages the front diff when I shift to 4hi 4lo
stick boot and rubber insulator "I have the rubber pad that helps reduce noise and vibration dampening, but I decided not to install it as I wanted to be able to fill the tranny from the top, instead of below, lot more noise but whatever.
Optional
install new Ujoints "just to refresh my driveline, not needed for the swap"
Install new differential seal and pinion yoke "this is optional, I want a fresh driveline, current one has 230k" Diff only has 15k miles on it, rebuild g80 but I didn't replace the yoke and it is kind of starting to oval one of the ears, "Should have known better"
As far as the tranny, it still had the original synchromesh and it looked like honey still, normal wear on the plug nothing funny, as far as I know the truck the tranny came out of only had 70k miles so it should have some life left, I still replaced the front and rear seals to avoid pesky leaks down the line.
So far it took me roughly 2 weeks to finish, that is after collecting parts for the last 5-6 months a little at a time, its little things that will add at the end and will nickel and dime you if you aren't careful. I would say it has cost me about 2k give or take, I could have done it cheaper but I kind of didn't want to skimp on parts, trans was about 1k shipped and delivered, I thought about getting a rebuilt, but you just never know with rebuilt stuff, I kind of like doing things my self, and I found a 2007 truck that was had some sort of branch or pole fall on it and it was totaled so I think I got a good solid unit. 07 was the last year for manuals incase you were interested, and the 3500s got better in the later years as opposed to the older years. They are a little noisier than the 4500s so if that bothers you, be warned if you are interested in the swap.
Its been a learning experience I still have a lot of work to do as I plan to restore the truck once I have the drivertrain sorted out. The way the engine pulls with out a torque converted is intoxicating so there is that! Running stock still, just a tune with a swapped manual section, drive fine pulls good, will keep updating as I go, for now I will take a break as I need to really clean the fat lady, shes been sitting outside for the past year with a bad torque converter and its filthy, will have to do a complete detail which wont be fun, as these things are massive.
Don't judge my carpet cuts, I will get a new one sometime in the future with new seats. Gotta do what you gotta do. Thats it for now, if you want more let me know! Thanks for reading and have a good day yall.
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