Sal's K2500 Dana 60 Solid Axle Swap

[strikk]

I temporarily welded the Ruffstuff perches o to the AAM11.5” 14bolt for gmt400 dimensions. Just about 4-3/8” inward from the outer axle flange on each side.

This marks the first time it’s on four wheels in a little over 3 years. Decided it was time to hook it up my k1500, drag it out, and position it in front of the barn bay to start really working on this thing.

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[Aparke4]

These trucks just look right with a SAS.

 

[TIM GAINOUS]

yup

 

[AirMdwn]

Good ****! Keep at it, it's all coming together nicely. What front springs are you running?

 

[strikk]

These are square body 47”, cheapest I could find at the time. Superlift +2”. Once the project is all together and the bugs are worked out I plan on calling ORD up for a custom set.

 

[Aparke4]

Strikk- did you ever consider a link kit like the one from WFO? If not, I know with the right leaf packs the flex on the SAS set up with leaf springs is quite impressive. I am already regretting my jump into the IFS lift world with my RC seeing how clean and simple the SAS kit is!

https://www.wfoconcepts.com/pr/Chevy-88-98-OBS-Builder-3-Piece-Cross-member/9463/20142

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[strikk]

Strikk- did you ever consider a link kit like the one from WFO?

Yeah, absolutely. When I saw the release of that crossmember from WFO a few months back I instantly wanted it but I figured I was already far enough down this project with the old school d60, heavy cummins, etc that i'd keep on down by current path.

Buuut my next project should totally be a super duty 60 with that link kit. Maybe a 5.3l swap

 

[strikk]

I've had the Cummins running but it wasn't as smooth as I would have hoped for. Educating myself on general tune up and engine timing I found some issues. Also took care of the internet famous killer dowel pin.

The TDC timing pin lost its nipple at some point in the past. Luckily I found it right where it broke off.... in the cam gear haha. retrieved that piece of plastic before it got in the way of something important and installed a new pin.

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Next up was figuring out where the current timing was. It was at least 5* off from factory spec, if not more, using my non scientific method of a timing wheel. I pulled the injector gear, aligned both pins and got it back to what should be factory 13.5* as long as no one has messed with the injection pump.

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Next up, valve adjustment. Intake and exhaust are expected .010 and .020, I had readings all over the place from practically 0 to .035. Put everything into its proper spec and torque, waiting on fresh gaskets to come in and i'll close it up. I must say though these valve look clean as hell. I havn't cleaned or wiped down a single thing on this engine

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[Aparke4]

It is so relieving to break down a motor and see the effects of routine maintenance!

OK so you are saying get rid of the 7.4 vortec gas guzzler and idle over rocks??! Haha

Are you running the factory turbo? If so what shape is it in?

 

[Silvio Iacuone]

Fantastic build. I am going to be doing a frame off rebuild on my K3500 just south of you in RI soon and I am planning on tackling the frame the same way.