Project Lead Sled

I am about to undergo my first LS swap. I picked up a Very Very clean 96 3/4 ton 2 wheel drive Suburban for $900. It has a blown head gasket but a new 4l80e transmission. I am calling it project Lead Sled.... L.S. ...L ead S led.... See what I did there? I am picking the truck up tomorrow. So far I have the mounts ordered have part numbers to order the sending unit adapters and have my eyes on a 6.0 under 100k miles. I think I can get the whole project done for around $3000.
I have a few questions though and I am sure that more will arise as I start into the build. So far here is what I am unsure about: 1) what do I need to do to make the 6.0 bolt to the 96 4l80e 2)Will all the gauges from the 96 work or do I need to get one of the new style clusters and fit it into the dash 3) Do I need a different torque converter... the truck has 3.73 limited slip gears. Thats all I can think of at the moment.
Any wisdom anyone can add to my build is GREATLY appreciated. I am in no way new to doing swaps of this nature but haven't done this particular swap yet. I own a 04 GTO currently so I am familiar with the LS family motors. I recently also converted a 88 Camaro to a LT1 and then sold it. I am doing this swap to create a dependable fuel efficient work truck for my contracting business. I just happen to LOVE the LS motors and this truck was too cheap to pass up. I will see about posting up some pics of the truck tomorrow.
I plan to delete the rear side and rear door glass and install tool boxes flush where the side windows are currently. It will look like the old style panel trucks only with a couple tool boxes on each side that can be accessed from outside the truck for convenience. I have photoshop so I will edit up some pics to illustrate this at some point so its a lil easier to see what I am going to do.

What year engine?

welcome! im doing a smilar swap myself. stock gauges will work fine and stock torque converter. you will need to slot the holes on the flywheel and add a spacer to make the 96 trans bolt up with the new motor. from what ive read this is one of the easiest swaps to do. im almost finished mine and its been pretty uneventfull. wiring was the main issue i was having but other than that the other stuff was pretty simple. good luck! oh and this guy redheartbeat helped me with alot hes full of info!

I am currently shopping for a motor. I expect to buy over the next couple weeks. I wish I could afford one of the 6.2s but budget doesn't permit. I want to get as much baseline HP and TQ as I can but still stay in my budget of around $1000. If anyone has a 6.0 for sale please get in touch. The wiring doesnt seem like it will be all that bad after doing the Camaro I just finished. I completely de-pinned the harness and went through it wire by wire. I think I can avoid doing that this time and just graft in the needed wires for the LS motor to run. I read your thread the other night Myzterray, looks like you about have yours whipped! I have always liked the two door Tahoes but they just aren't big enough for what I need.

What radiator is everyone using? The original radiator to the truck body or the radiators from the LS trucks???

yep, both kinds.

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Originally Posted by RedHeartbeat

yep, both kinds.

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So either radiator can be used? Any particular advantage or disadvantage to using one or the other? If I reuse the original sub radiator what is the easiest electric fan setup to use? I was also considering replacing the main seal and oil pan gasket before installing the motor but as I recall isn't the oil pan gasket a reusable gasket?

yeah, the original one will work but you'll need to retrofit fans. Do you have the 28" core or 34" core radiator?

Im unsure but I will measure tomorrow. Its a 3/4 ton so I would guess its the 34" core.

Picked up a new Optima yellowtop battery today along with AC Delco Iridium spark plugs and MSD plug wires. So far the tally on the build.....Truck $900, battery, plug wires, and plugs after tax $300.35 from Advance Auto and motor mounts from Ebay for $58.00. I will try to keep this tally updated as I go for a reference for others thinking about performing this swap. I didnt get a chance to measure the radiator today as I was at the hospital all evening with my sister who just gave birth to my newest nephew Damien Robert.

[IMG]http://i466.photobucket.com/albums/r...tsnirth002.jpg[/IMG]

Just curious on every ones thoughts... should I go with the 6.0 or the 5.3? I tow random trailers somewhat regularly along with towing my GTO to shows, I carry a fair amount of tools everyday, I intend to upgrade to 4x4 later on and possibly add a plow. I am sure the 5.3 could do it but would the motor be working too hard? Will my gas mileage be better with one over the other? Any thoughts are appreciated...

Depending on how you drive it and what you are pulling the 5.3 will get better gas mileage. 6.0's aren't known for gas mileage but that 5.3 will be working harder with that heavy suburban and a trailer. It could possibly get better with the 6.0 when loaded. I would go ahead and look for the extra displacement but don't rule out a 5.3 if you find an exceptional deal. And if you get an earlier 6.0 i believe it will already have a crank spacer that you need to mate to the tranny.

Good info thanks! I got a chance to do a lil work on her today. I bought the truck without ever hearing the old 5.7 even crank so I dropped a battery in today added some gas and gave her a shot of ether and it fired right up and purred like a kitten! it has a slight miss on the low end, I'm guessing due to the head gasket and need of a tune up. I popped a brake line the first time I hit the brakes so theres a xtra expense I hadnt figured for. I measured the radiator today, it's a 36" core. So back to a earlier question, what's the best E-fan setup to run with?

I like the 2005+ electric fans from the Silverado and Tahoe lines. If you want to attempt to build your own relay setup for the fans there are a few schematics on here. You can also buy a factory relay setup, it's built into the fog light harness, IIRC. Another option is to buy an aftermarket custom harness like the NelsonPerformance model or those available from Painless Wiring.

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Originally Posted by RedHeartbeat

I like the 2005+ electric fans from the Silverado and Tahoe lines. If you want to attempt to build your own relay setup for the fans there are a few schematics on here. You can also buy a factory relay setup, it's built into the fog light harness, IIRC. Another option is to buy an aftermarket custom harness like the NelsonPerformance model or those available from Painless Wiring.

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Im pretty good with wiring so I think I am gonna do all the wiring myself. I think I can just wire the fan signal wire from the 6.0 PCM into the 96 relays and then add the proper connectors for the fans I end up with. Sounds like I need to make a trip to pull a part and see what I can find. After getting that boat anchor to run I took it for a ride around the block and it made me so AMPED I am doing this swap. That 5.7 doesnt feel like it will get out of its own way without a good amount of work.
Has anyone heard of or had experience with SW engines? They shot me a quote on a 44k miles 2003 6.0 for $1400 shipped. Seems like a decent price for that low of miles...

http://www.crutchfield.com/S-oZhgzwo...ml#details-tab

Thinking about retrofitting this in...... anyone have one or familiar with it? I found it on ebay for $278.00 so seems like a good deal.

Also found this after hours of searching so thought I would share it. It looks like a good product but I am unfamiliar with the company making it.

http://www.thedetailss.com/95-99_CK_Double_Din.html

I almost have the old 5.7 ready to pull. Still have mounts and some body teardown to do before I pull it.

Quote:

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Originally Posted by LeadSled96

I am currently shopping for a motor. I expect to buy over the next couple weeks. I wish I could afford one of the 6.2s but budget doesn't permit. I want to get as much baseline HP and TQ as I can but still stay in my budget of around $1000. If anyone has a 6.0 for sale please get in touch. The wiring doesnt seem like it will be all that bad after doing the Camaro I just finished. I completely de-pinned the harness and went through it wire by wire. I think I can avoid doing that this time and just graft in the needed wires for the LS motor to run. I read your thread the other night Myzterray, looks like you about have yours whipped! I have always liked the two door Tahoes but they just aren't big enough for what I need.

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yea man its kicking my arse! hopefully this week ill be able to mess around with the wiring.

Quote:

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Originally Posted by LeadSled96

http://www.crutchfield.com/S-oZhgzwo...ml#details-tab

Thinking about retrofitting this in...... anyone have one or familiar with it? I found it on ebay for $278.00 so seems like a good deal.

Also found this after hours of searching so thought I would share it. It looks like a good product but I am unfamiliar with the company making it.

http://www.thedetailss.com/95-99_CK_Double_Din.html

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i started off doing sound systems and i always loved jvc products. definitely more bang for your buck!

Well I bought a engine tonight. I got a 2003 LQ4 with cable operated throttle, all accessories, PCM, wiring harness, and MAF, and aluminum heads for $1400 bucks shipped. Motor has a hair over 100k miles on it. Now if I can just get enough time off work to get the old motor out, the wiring prepped, and the engine bay painted I will be in good shape! If anyone needs a 96 5.7 vortec for a rebuild I have a complete motor for sale with all accessories minus a few sensors that I will be using for my swap. I have ran/drove the engine and it runs well. no ticks or knocks, good oil pressure and voltage from the alternator. It has a blown head gasket though and will need repaired or rebuilt at your discretion. The odometer says it has 141,000 miles. I would like $200 for it. I also have a video of the motor running prior to me beginning the removal process. I can ship it to anywhere you like as long as you pay for shipping.

Motor arrived yesterday. Exactly as described and he threw in a MAF sensor for me for free! Today I got most of the LS harness removed from the motor and ready to be modded as needed. I am yet unsure if I need the flywheel spacer to mate the 2003 6.0 to the 1996 4l80E. Can anyone shed some light on this for me? The fly wheel looks flat and NOT dished to me but I will post up a picture if that helps..

[IMG]http://i466.photobucket.com/albums/r...ration/028.jpg[/IMG]

[IMG]http://i466.photobucket.com/albums/r...ration/026.jpg[/IMG]

http://i466.photobucket.com/albums/r...ration/034.jpg

Have another question....What will I need to do to the wiring harness on the 6.0 to make it operate the 1996 4l80E trans in the Suburban? The motor must have had a 80E behind it already since it has the flywheel with 6 bolt holes for the torque converter.

Made some progress tonight finally!!!! The old 5.7 is sitting on the ground in my garage. I will have the motor stripped of all the sensors I need to swap over and the trans bolted to it this weekend. HOPEFULLY will have it in the truck Sunday night but that might be a bit optimistic since I have to work all weekend too. Im hoping I dont need the flywheel spacer to bolt the motor and trans together but I will find out soon enough I guess. I made a chart of the wiring pins that I need to swap over from the 5.7 harness to the 6.0 harness for things like the MIL light, fuel pump relay, brake signal wire, etc. if anyone is interested or wants a copy I can post it up or PM it to you.
I have done a lot of surfing around on the site as well as on the net but I cant find anything to tell me if I need to do anything special to make the PCM for the 6.0 control the 1996 4l80e. Does anyone have any wisdom they could impart upon me in this area or a post they could point me to that I might have missed for some reason??? Last question I have is about the drive shaft, I went with the cheap ebay motor mounts instead of the Dirty Dingo mounts, will I have to shorten the drive shaft because of this? If so then I will order the Dingo mounts if that will alleviate the issue. I am sure it would be cheaper than having the drive shaft shortened.

http://i466.photobucket.com/albums/r...eshopfloor.jpg

It's been a while! I have been busy! I was offered a job and took it so they have been working my ass off! I have managed to get a little done on the truck. The motor is sitting in the truck! I finally got the trans to mate properly. That was a nightmare! A friend of mine runs a speed shop and he said from time to time he has to tap the converter on with a mallet while standing the trans on its tail shaft. It took me a couple trys but I finally got it. Everything is hooked up now. I have all the fluids changed and sealed up. There's a new starter on her. The accessories are on though I still need to grab a tension pulley. The radiators is in and hooked up and the system thoroughly flushed . Trans lines on, crossmember bolted up. The dingo mounts made it so freaking easy! We dropped the motor in and grabbed the trans x-member, we weren't quite in the right spot so we took a 2x4 at the front of the motor while I layed under it to see when we were in the right spot. Very little effort and it dropped right in place. It took all of about 30 minutes to have the motor completely set in place and bolted up(all hand tools)! Well worth the money spent on the mounts! I HIGHLY RECOMMEND DIRTY DINGO MOUNTS!!!!!!!! Let's see what else, OH I got the dash all apart and cut up for the install. Now I just gotta man up and fiberglass it all in properly. I'm currently working on getting the motor wired up. I have the harness tagged, de-pinned, and sorted just got connect it all route the wires where I want them and then get gauges working. Before I split the harness I did turn the motor over a few times and got it to fire! I can't wait to get this thing done and drivable! I'm plan on using it to trailer my goat to LS fest in Bowlng Green in September. So I gotta get it running soon so I can get some seat time in it before we make the trip. It's only 4.5 hours but I don't wanna break down with my wife and six month old. That would be horrible! So anyways that's where I'm at. I'll try to get some pictures posted up soon. There's so much room between the radiator and engine I'm thinking there's gonna be a front mount turbo in my near future! The new job supplies me a work truck and pays for fuel so I can get a little crazy on my toys now since I don't have to drive them everyday.