My 5.3 Engine swap

[amrg]

Do you mind posting part numbers/prices/links of everything you got in 1 place so anyone interested in following can know what to expect?
Good luck on the build!

 

[humvee]

At the moment, the parts I need are as follows: UPDATED PARTS ON PAGE 7

Bell Housing - ACDELCO 24236707
Power steering pump - ACDELCO 25932020
Input Drum w/reluctor - http://www.bulkpart.com/2/product/D74554GA.html
Engine mounts - http://www.currentperformance.com/shop/04-08-colorado-canyon-v8-engine-mounts/
Alternator pulley mount - n/a
AC Compressor - ACDELCO 1522146
AC Compressor mounting bracket - n/a
Custom or alpha specific AC lines - n/a
Custom or Alpha fuel lines - n/a
Air intake assembly - http://www.wholesalegmpartsonline.com/showAssembly.aspx?ukey_product=3033947&ukey_assembly=391908
Exhaust manifold - http://www.discountoeparts.com/auto-parts/2009/hummer/h3/alpha-trim/5-3l-v8-gas-engine/exhaust-system-cat/exhaust-manifold-scat
Custom or alpha downpipe / exhaust - n/a
Engine Oil Pan - http://www.currentperformance.com/shop/gm-muscle-car-oil-pan-kit/

I'll update the n/a parts as I go along, and add more to the list.

 

[CaseyS]

You will need this

http://ww2.justanswer.com/uploads/AS/ASEMaster35yrs/2013-05-06_034613_700r4-4l60e.jpg

And here are the best videos on the web that I used for my teardown

https://www.youtube.com/watch?v=BQgQIyIhI0o

And rebuild

https://www.youtube.com/watch?v=EkyPoeAcxOI

And this for some bathroom reading of you get really bored

https://www.dropbox.com/s/q14qjpo7mgqprz2/4L60E.pdf

 

[humvee]

Wow C thank you, I'll study these and put em up on a board for the guys.. My mechanic buddy went nuts when I told him I was opting out of the tranny upgrade kit..
Do you have a link to the kit you got? I looked through the threads but didn't get anywhere.

My better half is gonna be thrilled...

 

[JPaul]

I'm glad to see a detailed thread about doing this swap into a 2008+ model, now I can see just what all will go into it if I decide to do the same with mine. Everything else I had found was for 2006-2007 which have several differences in the swap, but it was never clear what exactly they were.

 

[CaseyS]

More information for you. That seal that you have listed looks like the teflon o-rings that go on the input shaft. There are 4 of them. GM requires a special tool to install them and then compress them back down into the grooves. If this is not done right, you will get cross leaking and the transmission wont function right. I think on the 300mm shaft there is also a small o ring that goes on the end. If you don't have all of these little parts you may be sitting a long time waiting on shipping.

I found this site that has an older style shaft (this one won't fit your application) that comes preloaded with rings, clutches ready to install.

https://www.gmtransmissionparts.com/remanufactured-performance-input-drum-assembly-4l60e-1993-up/?gclid=Cj0KEQiAq920BRC8-efn57XrotYBEiQAlVlMQ7SXLb0zKtf1iZVi-DlgiV6o1FJ-WmAH3ekwF11hokwaAngx8P8HAQ

You may want to reach out to them and see if they could build you up one with the 2006 up input drum just like that one. Note that this is a reman drum, but you get everything in it for almost the same price as a new drum. This would save you a LOT of work.

Link to the shaft seals

https://www.gmtransmissionparts.com...i9RK4o1kP6t-Uq2aAQnssT9k7eQdM-ZyXMaAh2f8P8HAQ

I also searched and there are videos for installing the teflon rings without tools but I haven't watched any of them yet if you have to go that route.

 

[CaseyS]

For rebuild kit something like this

https://www.gmtransmissionparts.com/4l60e-4l65e-4l70e-2007-2013-master-transmission-rebuild-kit-w-bonded-vb-plate/

That kit has raybestos high energy clutches.

This kit has the borg warner clutches which I used in my build

http://www.bulkpart.com/2/product/74009ED-BS.html

Either way you will need to order the hummer specific filter to go with it, standard filter wont work.

And this seems like a good buyers guide for the kits

https://www.gmtransmissionparts.com/700r4-4l60e-4l65e-rebuild-kit-buyers-guide/

You should consider the minimum upgrades, the sun shell and corvette servo, around $70 for both of those.

Considering how far away you are, buying a master rebuild kit may be some good cheap insurance on having all the soft parts on hand in case you need anything, even if you don't do a full rebuild.

I feel your pain. In my swap, I thought the transmission would be the easiest part, just by the engine adapter and bolt it right back up. I learned the hard way that the I5 bellhousing and input are stepchilds and not standard checy pattern stuff. I probably spent half my swap time just on transmission. I would have just dropped stuff at a shop, but I was unsure of the combination of parts needed so I had to slog through it myself. I ended up buying a burnt trans from a 98 Z71 that had the input shaft and bellhousing I needed and did a full rebuild when I made one transmission from two. It is a little intimidating at first, but if you watch the videos and follow along, if you have decent mechanical skills its not to bad to go through the whole thing. I did have to McGuyver a few things to compress the retainer springs to get some of the pistons out.

Good luck and post anymore questions up!

Edit: reference post #3 in this thread. Did you think you would end up here?

 

[humvee]

I'm beginning to wrap my head around an issue that worries me. The general perception here in the Gulf is that when you open up your transmission, it will only go downhill from there.
Looking at how intricate it all is, its easy to see why.

I'll read this and involve myself heavily every step of the way, Thanks again casey this is awesome material.

 

[humvee]

I imagine buying a tranny off an alpha in the US, then shipping it here would be a shipping quote disaster. I'll try closer places like scrap yards in Dubai over the weekend. If I don't get a hit, I'm going the rebuild route.

Will update with pics and post questions as I go.

 

[humvee]

You should consider the minimum upgrades, the sun shell and corvette servo, around $70 for both of those.

This is very reasonable, but I'm reading more through the material, everyone stresses on the importance of purchasing a new torque converter whenever you rebuild a tranny. I was just going to use the one that came with the engine, which has 90k miles on it.

Adding to list.

 

[amrg]

Most major rebuild kits from brand names come with a torque converter (those have a stock stall rating of ~ 1600)

 

[humvee]

Most major rebuild kits from brand names come with a torque converter (those have a stock stall rating of ~ 1600)

Im only upgrading known weak points of the 4l60


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[CaseyS]

The main reason for the torque converter is if you are at the point that your transmission needs a rebuild, chances are you have clutch material, and possibly more in the fluid of which flows through the torque converter. It would be ashamed to spend all that time and effort on a rebuild to only when you fire it up the first time, fill it with trashy fluid from a used torque converter.

If your torque converter came from a known good transmission, you are probably ok. Inside the torque converter is the lockup clutch which over time can wear the same as the clutches in the trans. A large part of a transmission overhaul is physically getting it out of the vehicle, especially a 4x4 where you have to pull a transfer case and both driveshafts. The logic follows, that if you have it down and apart, might as well service it head to tail while its out, as a shortcut could lead to an equally labor intensive job of pulling it again.

 

[rsc]

Don't let it get you bogged down in self-doubt because of the many small parts. If you had the 3? GM installation tools for all the seals and such then you could pretty easily build it up by watching the videos. Sure there are a lot of strange parts, but once you break it all down into more manageable, related chunks it is a lot easier to understand. Remember the old question- "how do you eat an elephant? One bite at a time." However, if you can find a good, low mileage 4L60E from another V8 it would be a lot simpler.

 

[humvee]

Thank you for your explanations and kind words. I've been locked up at work for the past few days setting up next week's filming schedule and haven't had time for a proper update.
Reached out to gmtransmissionparts and waiting for Monday to come with a reply.. Going for an assembly like Casey recommended (if available).

For now the 3 is in my driveway pending these parts and some accessories. This will take a little while longer.

Looking back, the only thing I would've done differently is wait until I find an alpha engine with its tranny.
Everything else seems very straight forward.

I'm determined to finish this build before offroad season is interrupted by the 130 degree summer. And got my fingers crossed for a mid-travel ifs solution for next year's build.

More soon


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[CaseyS]

Any updates on this? Since I last posted in this thread I had to pull my transmission down and do a partial rebuild due to a cracked input shaft.

 

[humvee]

Hi C. Well I have all the parts except the exhaust manifold.
So the tranny comes off early March. Any tips?


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[4speedfunk]

Diesel Hijack....
https://www.youtube.com/watch?v=0MB-iqfCMSA

 

[CaseyS]

What did you end up doing on an input drum?

FWIW, I cracked my input drum, so I went back to my local trans shop. Reman input drum, reman reverse drum, full rebuild kit, band, plus an extra 3-4 clutch and 6 0.076 steels for $376 out the door tax and everything. Did a 2 1/2 day turnaround. Crappy work and I was tired as heck afterwards.

Just thinking, did you get the torx 50+ bit to get the bellhousing free from the case? Its a special torx, regular torx 50 won't work and will strip the bolt head.

http://www.amazon.com/OTC-TORX-PLUS-Socket-Square/dp/B000O846UI

Edit: Can you snap a pic of your existing input shaft? I think all 3.5/3.7 run the 245mm converter which is what yours should look like. The 300mm is what you will need if you want to confirm your new input drum. The other two on the left are early styles. All LT and 4.3 based engines ran the 30 spline shaft which is what my setup requires.

 

[humvee]

Can you snap a pic of your existing input shaft?

C! So sorry I didnt see this. I just got back from vacation and ready to get started again.
Surely will take a pic as soon as the drum is out, which should be in great condition. Let me know if you or someone else needs it.

Which brings me to the rest of my 3.7 accessories, some i'll give away at shipping cost, others I might sell. Just have to take the time to set this up.

Now for that update. I was struggling with getting new exhaust manifolds over here, only major sites sold the left one and it was quoted at $500 shipping, so I had to find other means.

Harness is ready, I'm getting the 300mm input drum from the dealer and the tool Casey shared a link to. Unfortunately, won't be upgrading the tranny even though I know I'll regret it later.
Maybe I'll do that or a 6 speed when something comes up.

I'm going to continue with a detailed update as soon as the rest of the parts come in.



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[humvee]

The H3 is back in the garage!

Harness needs another 3 days to get here and I'm very excited. Jamie concluded the battery terminal and updated the PCM TCM firmware for the V8.

The tranny is being pulled apart as we speak and should be finished with the input drum by Thursday. The torx 50+ bit was essential, up until now, they were improvising by welding the screw drivers to the bolts and twisting them that way. So thank you Casey.

Went scouting for the last couple of parts yesterday and got them. I found a bell housing unit that fits, and an alternator mount bracket. I couldn't find bracket pn: 12567922, which is the one for the H3, Colorado and GMC Sierra... Instead I got it off a 5.3 Yukon. It bolts right on but touches the vacuum pipe with the orange tip. Mechanic said we can just bend that out of the way and call it a day.

Who thinks this is a bad idea?

Will take pictures later today of all the accessories mounted on the engine, I'll then update the parts list needed to make this swap.
Here's a close up of the new engine mount.

 

[humvee]

So harness 3 day shipping was quoted at $650... Ridiculous.. I opted for an 8 day delivery for around $150.
And no proper work has been done on my tranny yet. I was hoping to have the 3 up and running by now.

This is beyond the control of my mechanic, and Jamie, who was shocked at these shipping quotes. So I thought I'd take to the forum and vent my frustration at something else.. gmpartsdirect.com:

After ordering the v8 exhaust manifolds, using their PayPal portal to facilitate the payment.. I was charged the full $180 for the parts + shipping.
I didn't hear a word from them for 10 days, then they sent me a new payment request for the same amount again. I shared the transaction ID, and a screenshot of my bank statement in a few Emails back and forth.. They refused to acknowledge that the manifolds have been paid for and have now stopped responding to my Emails completely.
I bought a new set elsewhere, and starting to feel like I should forget all about the $180. Its one thing to have to put up with ridiculous logistics fees, but a whole other thing to be far far away and helpless!

Anyway.. Will update ya'll soon when my parts get here.


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[humvee]

You should consider the minimum upgrades, the sun shell and corvette servo, around $70 for both of those.

Hi Casey, I have some tranny questions.
Seeing that the work might take time. I'm going to take your advice and do the minimum you mentioned above. Sun shell and servo.
The guide you sent led me to these two parts:
https://www.gmtransmissionparts.com/upgraded-corvette-2-4-servo-700r4-4l60-4l60e-1982-up/
https://www.gmtransmissionparts.com...-heavy-duty-washer-style-700r4-4l60e-1982-up/

Does this seem right to you?

Also, I've been looking at the diagram, when replacing the input drum, will they have to go through the shell and servo anyway? Or is this on another part of the tranny and requires more dismantling to get to?

I'm only asking because I want to keep dismantling tranny components to a minimum, and reduce the risk of something going wrong when putting it back together.

 

[4speedfunk]

They refused to acknowledge that the manifolds have been paid for and have now stopped responding to my Emails completely

Not surprising given the number of offshore scams these days. Your location may have a lot to do with the response (or lack of). PayPal should cover you.

 

[CaseyS]

The servo can be changed from the outside with the trans in the vehicle, so not really any additional work. You will want to purchase the $14.95 one with all the sealing and o rings since a) the pistons are different sizes than what its replacing and b) its difficult to get the servo out without cutting the last outer o ring.

With regards to the sun shell, its the next component down after you pull the input drum. The front planetary should pull right out and then the sun gear, then the sun shell. Can't remember now if there is a snap ring involved or not.

Hope this helps.