90W7's --91' K2500 build +5.3/4l60e swap (NEW)

[90W7]

NEW STUFF
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I painted up some dash pieces and got in some other goodies.

1. ARP Header bolts
2. Ebay CAI
3. New cluster lens-LMC
4. PRNDL unit +cable-LMC
5. Knee bolster vent cables-LMC
6. Cluster LED's (blue)-Superbrightleds.com
7. Autometer sending unit adapter kit
8. Autometer Cobalt series Gauges:

• Vac/Boost (might as well only buy the gauge once should i do a super/turbo)
• Trans Temp
• Wide Band O2

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Another expensive yet very worth it investment was the HPTuners software which allowed me to remove the PCM VATS, EVAP, and to delete the rear O2 sensors. As well as what im learning to do now which is to tune for the cam i put in. I got the truck running last fall but i had to command the truck to idle @800 Rpm otherwise it would start to idle erratic and eventually die. It started snowing just days after so this is is where i had to park it for the winter.

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Very first start:
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I Ordered the GM beginners course for tuning which covers the tuning process for Headers, Heads, Cam and other supporting mods from The Tuning School. Its another chunk of change but very worth it if you want to get into tuning. Ive actually been tweaking my 2013 silverado a little bit and its pretty cool what improvements can be made.

Anyways ive changed the tune for the truck so it should idle a hell of a lot better when i upload it this spring and then it should be a little fine tuning from there.

 

[90W7]

Summer 2016
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With the swap basically done and running i was able to focus on a bunch of little things ive been meaning to do or things that have been driving me crazy that i needed to fix. My phone broke this summer and i lost almost all my pics of what i had done so ill post what i can.

• Tac module: i was getting a U0107 lost comm between the pcm and tac module which was sending the engine into reduced power mode every time i went over 1/8 to 1/4 throttle. After circuit testing i concluded the TAC module was faulty and a new one was ordered from summit which fixed it.
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• Exhaust: I finished the exhaust minus a tip. Full single 3" exhaust originally thru a super 10 (too loud w/o cats) but i went with a 50 series delta flow instead(and its still loud but not obnoxious) . I used hedman ball and socket flanges to connect the system to the off road Y pipe and then welded it all together.
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• Carpet/Seats: I ordered new charcoal carpet and found some nice GMT800 seats, center console and overhead console. The seats don't match but i will look into seat covers or just keep an eye out for some dark/charcoal color ones.
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• A-Pillar gauges: I finally wired them up and installed the wideband O2
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• Brakes: I bought new loaded calipers and new rotors for the front, replaced the rear drum shoes and installed my procomp extended brake lines.
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[90W7]

Last updates of 2016. I didn't have as much extra money for the 91' as last year but still managed to get a bunch done. To be continued this spring: (new tint, buff/polish paint, wheels & tires, finish tuning with wide band etc..)



Coolant reservoir mounted and CAI angled back. I need to move the battery to the driver side and get a sealed intake system ( IATS are high. "hot air intake".

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Initial LTFT tuning progress. needs a little more work plus WOT tuning still needs to be done.

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LED cluster upgrade: Very worth it.

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Tach plus pillar pod installed.

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Oil Change again.

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Swapped out the Super10 for a 50 series delta flow.

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@90W7

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[90W7]

May 2017
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Summer 17'.

With the snow mostly melted i threw the battery back in the 91' and decided to get back on my project.

I recently bought the combo ive been wanting forever 17x9 Mickey Thompson classic III's & 35x12.5R17 BFGoodrich KO2's

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Some other things for the truck:

• Lokar shift cable (rod linkage hits the headers)
• Transgo HD2 shift kit
• Energy suspension swaybar bushings/link kits
• Procomp black lugnuts
• Procomp 7.375" pushrods (needed shorter ones)
• DA polisher/pads with cutting and polishing compound

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Mounted, balanced and installed

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Next i pulled the fender flares off and washed,clayed, cut and polished the whole truck. Time consuming and far from perfect but it looks way better.

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[90W7]

Didn't do much today but I got the energy suspension sway bar bushings and links in + i drilled the holes for the drivers side battery tray and installed it.

I just need to switch the battery over to the other side and install the 5.3's original B+ cable to the starter. Then I'll have the passenger side free'd up for a sealed intake box.

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[90W7]

I found the source of the rattle ive been hearing. Despite having the reallift torsion bar re locators, my torsion bars were touching my transmission crossmember. heres my quick fix..

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Next problem was a annoying lifter tick on bank 1. With a fresh rebuild (less than 1k miles) and brand new LS7 lifters i didn't wand to chance having a cam lobe eaten or worse so after trying to quiet it down over a few weeks i decided to just replace the whole bank 1 lifters and my pickup tube O-Ring to be safe (if it was sucking air, hard to believe i could have damaged the O-Ring as i built the motor on the stand.)

I couldn't find the cause of the lifter tick, but between the new lifters and the O-Ring the sound in gone thankfully.

I also installed my Comp cams 7.375 hardened pushrods, Lifter preload is now .080 instead of the .105 with the factory "7.400" pushrods (they actually measured 7.392 FWIW)

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[90W7]

Fall/Winter 2017​

Not much new this fall/winter.

With the cold weather the headliner really started falling down so i decided to recover it.

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A few things i have to do within the next week:

• New heater core(flushing helped a little)
• New 4wd actuator w/harness(upgrade)
• Front diff axle seals(usual seep, but might aswell)

Things i need to do at some point:

• Consider adding a catalytic converter(smell and loud exhaust is getting old)
• switch to ceramic bake pads(brake dust is terrible on the new wheels)
• New headlights(yellow hazy headlights suck at night)

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[90W7]

I went ahead and bought the 4wd actuator, harness kit and new axle/tube seals.

The front diff started making bad sounds in 4wd a few days ago and i was hoping it was just the old thermal actuator not engaging all the way. Looks like its worse than i thought. The gear oil was perfect this summer so it must have started going south this winter with the 4wd use. (200k miles on the original diff so i cant complain too much)

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I ended up flushing the front diff, removing and cleaning the extension housing(inspecting for damage) It sounds like the driver side carrier bearing or the spiders)

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I decided to just install the new actuator, harness, seals and put new fluid in it for now.

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The new mission this week: Find a used diff to swap in or buy a rebuild kit and pull it and rebuild it . 2wd and a open rear diff sucks in the winter time. i hate to do this twice since i want to regear the truck to 4.10/4.11's but i don't think i want to wait until summer with only 2wd.

 

[90W7]

I'm a genius...(an idiot). I didn't realize the front driveshaft u joint @ the tcase was toast. I ended up replacing all u joints on the front and rear driveshafts.

Good thing too because several were dried up and worn out. (they looked fine externally)

No more noise or vibration & the front diff is all good.

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