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Old 09-15-2013, 06:34 PM   #1 (permalink)
JSarge
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JSarge's '95 to '88 swap

Alright so ill break down what my intentions are. Dont try to talk me out of it!

We have an '88 C3500 (GMT 400) ECLB, in immaculate condition. Originally had a 454/TH400 combo. We swapped in a 4.3L V6 with the intentions of gaining superior fuel mileage with a single turbo/carb setup, however we moved on from that.

I also have my '95 C3500 with a perfect running low mile 6.5. We decided were going to use this truck as a donor to do a 6.5 swap into the '88, and sell the '95 as a rolling chassis.

I am in the process of getting everything together to get er done. However there are a few primary things in mind which i would appreciate some advice towards.

1- We want to mate the TH400 with the 6.5. Its a freshly rebuilt trans. What do we need to feed the trans the correct vacuum? Does it have to be regulated or can we use the 6.5 vacuum pump? I know they mated these behind 6.2's so its clearly possible. Also, as far as the flexplate goes, im assuming we will need to re-drill the 6.5 flex plate to adapt to the older style torque converter pattern (3 bolt vs 6) unless there is a plate that will retrofit.

2- Most people will laugh, but we are on the debate of keeping the DS4 setup or swapping to a DB2. Yes, a DB2 will make this swap go a LOAD quicker and more than likely overall better. However, with a COMPLETE DS4 setup at hand with all wiring and a low mile injection pump, we are considering saving the cash and keep it as is. Again as stated above we want to use the TH400, so on that note, could we go with an ECU/PROM that is setup for a 5 speed and allow the ECU to figure transmission control is standalone?

3- If we decide to go with the DS4 swap, obviously all engine wiring would be carried over from the '95. That being said, im assuming we would have to remove the dashboard's to collect all of the required body harness also? Or could we sacrifice the gauge cluster and relocate the diagnostic port?

I will be posting pictures as i go, like i normally do.. So subscribe! Thanks alot DP!

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[ '95 GMC C2500HD SLE 6.5TD 4L80E/G80/3.73 "F" TRIM - Ext Cab/Long Box ] Rebuild Thread: Click Here!
Vac pump del DE 3" down pipe w/ 4" straight pipe exits before axle H/O water pump 195 degree tstat
Manual Boost/Fuel Pres gauges Walbro FRC-10 Lift pump FFM delete Volvo marine water seperator/filter
Bumper mounted FSD Home made TM @ 10 PSI Lube specialists oil line's Rebuilt 506 w/ ARP main studs


[ '88 GMC C3500 DRW SLE 6.5TD TH400/DANA 80/4.10 "F" TRIM - Ext Cab/Long Box ] Rebuild Thread: Click Here!
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Old 09-15-2013, 06:58 PM   #2 (permalink)
turbonator
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get a flexplate from a 4l80e, the flex plate is the same as a diesel th400 flexplate, the gasser one is different, with different tooth count and pitch... also you will need your bigblock convertor( not a problem if you used the same convertor behind the v-6), or a diesel convertor, they are the same from 454 to diesel...

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1998 gmc 3500 RCLB/4X4, 4L80E, DB2 converted, 6.2l #599 casting, bored .040", water-cooled garrett gt3271G turbo, CTS manifold, j-code intake, .290" IP, delphi injectors popped to 2300PSI with modded tips, 3" D.P., aero stainless muffler, triangle tip side pipe, Holley Red lift pump @ 5PSI, canton racing oil filter delete, remote filters, custom 5000psi gates oil cooler lines, over-sized long oil cooler, over-sized hayden tranny cooler, other than that its a "stock" engine....


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Old 09-15-2013, 07:02 PM   #3 (permalink)
Glagulator
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The diesel/auto tranny combos had a vacuum pump on the oil pump drive and a vacuum control/throttle position valve on the IP to control the tranny. I still have a box full of those valves somewhere. I'm not sure how you would get it done with a DS4. Maybe someone makes an adapter for this situation.
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99 CREW LONG SRW C3500 work truck 199k+ mi. orig. motor & trans 4.10, modded engine harness, new oil cooler & lines, all new front end parts and poly bushings, trans poly mount, all new brakes.
96 SUBURBAN K2500 wife's truck 210k+ mi. orig. motor & trans, 3.73...
95 C2500 Suburban 6.5td HO w/p, timing set, HB & pulley, all rubber hoses, modded engine & main harness, converted to OBD2, PMD to bumper...
95 C1500 Suburban 6.5td rebuild tranny, convert to DB2, replacing as many parts as I can.
96 C2500 Suburban 7.4L converting to 6.5td w/ DB2, 4L80, 3.73
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Old 09-15-2013, 10:19 PM   #4 (permalink)
JSarge
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Quote:
Originally Posted by Glagulator View Post
The diesel/auto tranny combos had a vacuum pump on the oil pump drive and a vacuum control/throttle position valve on the IP to control the tranny. I still have a box full of those valves somewhere. I'm not sure how you would get it done with a DS4. Maybe someone makes an adapter for this situation.
Well, looks like i will be pushing more toward doing the DB2 setup, just maybe i can find a good used pump on here.

If you could dig that stuff up, maybe shoot me a PM and we could work a deal out?

Also, i have both a 4L80E flex plate and my old 454 converter. Looks like i should be in good shape for that.
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[ '95 GMC C2500HD SLE 6.5TD 4L80E/G80/3.73 "F" TRIM - Ext Cab/Long Box ] Rebuild Thread: Click Here!
Vac pump del DE 3" down pipe w/ 4" straight pipe exits before axle H/O water pump 195 degree tstat
Manual Boost/Fuel Pres gauges Walbro FRC-10 Lift pump FFM delete Volvo marine water seperator/filter
Bumper mounted FSD Home made TM @ 10 PSI Lube specialists oil line's Rebuilt 506 w/ ARP main studs


[ '88 GMC C3500 DRW SLE 6.5TD TH400/DANA 80/4.10 "F" TRIM - Ext Cab/Long Box ] Rebuild Thread: Click Here!
SOLD

6.5 FAQ L@@K!: Click Here!

Last edited by JSarge; 09-15-2013 at 10:20 PM.
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Old 09-16-2013, 08:46 AM   #5 (permalink)
JSarge
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Found the part number for the vacuum regulator to mount on the side of DB2 pumps. Would replace the TPS sensor on a 92-93 6.5. Since i will be using a turbomaster, i think the belt driven 6.5 vac pump will be just fine for that. Any input appreciated.

Now, if anyone has a good DB2 pump laying around, LET ME KNOW! =)
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[ '95 GMC C2500HD SLE 6.5TD 4L80E/G80/3.73 "F" TRIM - Ext Cab/Long Box ] Rebuild Thread: Click Here!
Vac pump del DE 3" down pipe w/ 4" straight pipe exits before axle H/O water pump 195 degree tstat
Manual Boost/Fuel Pres gauges Walbro FRC-10 Lift pump FFM delete Volvo marine water seperator/filter
Bumper mounted FSD Home made TM @ 10 PSI Lube specialists oil line's Rebuilt 506 w/ ARP main studs


[ '88 GMC C3500 DRW SLE 6.5TD TH400/DANA 80/4.10 "F" TRIM - Ext Cab/Long Box ] Rebuild Thread: Click Here!
SOLD

6.5 FAQ L@@K!: Click Here!
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Old 09-16-2013, 10:57 PM   #6 (permalink)
wolfhunter1256
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I am just about done putting a 6.5 turbo (hx-40wii) in a 1995 chevy 1500 4x4 swb . It was a project and I have done a few diesel conversions . The vac pump you have will work fine on a 400 thats what i'm running for a trans too. You need your hydrovac booster for brakes , a acc cable if you use a db2 for a 92-3 6.5 and the wiring good luck ! I got a diesel cluster but my harness don't have the blade for glow plug light in dash ,I like things like they are suppose to be. I have clipped my gas harness clean ,used a harness out of a 88 chevy bus for the glow plug part. I am still having problems with my speedo not working . Also put a diamond eye 4' exhaust on just cut about 2 foot out.
Theres a guy on KC craigslist with a new rebuilt db2 for $100

Last edited by wolfhunter1256; 09-16-2013 at 10:59 PM. Reason: more to say
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Old 09-19-2013, 09:35 PM   #7 (permalink)
JSarge
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Picked up a DB2-4911 with lines today.

Its a used pump with mild miles on it, any recommendations on checking anything out before i set it up? Spins nice and all terminals look to be strong and intact.
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[ '95 GMC C2500HD SLE 6.5TD 4L80E/G80/3.73 "F" TRIM - Ext Cab/Long Box ] Rebuild Thread: Click Here!
Vac pump del DE 3" down pipe w/ 4" straight pipe exits before axle H/O water pump 195 degree tstat
Manual Boost/Fuel Pres gauges Walbro FRC-10 Lift pump FFM delete Volvo marine water seperator/filter
Bumper mounted FSD Home made TM @ 10 PSI Lube specialists oil line's Rebuilt 506 w/ ARP main studs


[ '88 GMC C3500 DRW SLE 6.5TD TH400/DANA 80/4.10 "F" TRIM - Ext Cab/Long Box ] Rebuild Thread: Click Here!
SOLD

6.5 FAQ L@@K!: Click Here!
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Old 09-20-2013, 06:04 AM   #8 (permalink)
turbonator
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Quote:
Originally Posted by JSarge View Post
Picked up a DB2-4911 with lines today.

Its a used pump with mild miles on it, any recommendations on checking anything out before i set it up? Spins nice and all terminals look to be strong and intact.
If you are planning on FTB, pull the inlet housing off to drill it, there is a screen for the transfer pump that can then be removed to check for debris.....sometimes find bits of degraded fuel line chunks on it.
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Building power "Sanford and Son Style"

1998 gmc 3500 RCLB/4X4, 4L80E, DB2 converted, 6.2l #599 casting, bored .040", water-cooled garrett gt3271G turbo, CTS manifold, j-code intake, .290" IP, delphi injectors popped to 2300PSI with modded tips, 3" D.P., aero stainless muffler, triangle tip side pipe, Holley Red lift pump @ 5PSI, canton racing oil filter delete, remote filters, custom 5000psi gates oil cooler lines, over-sized long oil cooler, over-sized hayden tranny cooler, other than that its a "stock" engine....


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Old 09-24-2013, 01:17 PM   #9 (permalink)
JSarge
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So we have just about everything planned out.. However, we are debating on what we want to do for a Tach and Alternator.

We have two alternators available. One from the '95 truck, and one from the carbureted gasser setup. They both have the same mount pattern.

Obviously, i need to snag a tach that reads from alternator output (any recommendation for something affordable is appreciated) .. however, which alt should we plan to use? Would we be able to use the gasser's alt and expect the ability of a tach read out? If not, will the '95 alt be usable without the ECM in play?

Thanks guys...
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[ '95 GMC C2500HD SLE 6.5TD 4L80E/G80/3.73 "F" TRIM - Ext Cab/Long Box ] Rebuild Thread: Click Here!
Vac pump del DE 3" down pipe w/ 4" straight pipe exits before axle H/O water pump 195 degree tstat
Manual Boost/Fuel Pres gauges Walbro FRC-10 Lift pump FFM delete Volvo marine water seperator/filter
Bumper mounted FSD Home made TM @ 10 PSI Lube specialists oil line's Rebuilt 506 w/ ARP main studs


[ '88 GMC C3500 DRW SLE 6.5TD TH400/DANA 80/4.10 "F" TRIM - Ext Cab/Long Box ] Rebuild Thread: Click Here!
SOLD

6.5 FAQ L@@K!: Click Here!
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Old 09-24-2013, 01:39 PM   #10 (permalink)
Glagulator
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The stock tach gets the signal direct from the alternator (white wire). You just have to be sure to use the correct pulley (diameter) for a diesel.

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99 CREW LONG SRW C3500 work truck 199k+ mi. orig. motor & trans 4.10, modded engine harness, new oil cooler & lines, all new front end parts and poly bushings, trans poly mount, all new brakes.
96 SUBURBAN K2500 wife's truck 210k+ mi. orig. motor & trans, 3.73...
95 C2500 Suburban 6.5td HO w/p, timing set, HB & pulley, all rubber hoses, modded engine & main harness, converted to OBD2, PMD to bumper...
95 C1500 Suburban 6.5td rebuild tranny, convert to DB2, replacing as many parts as I can.
96 C2500 Suburban 7.4L converting to 6.5td w/ DB2, 4L80, 3.73
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