My 5.3 Engine swap

[CaseyS]

Also I just verified from my parts bin that my 06 also used the shorter 6 7/8" stator support, so that cross checks that length was used with the 245mm converter.

 

[humvee]

So I told the guys not to install the tranny, and shared your post with gmtransmissionparts. They came back with this.

"That makes a lot of sense, sounds like this dude knows his stuff. So it sounds like you need a pump stator tube and possibly a bellhousing? "

Flying out tonight for 10 days, but i'll be ordering parts and liaising with Sam's guys throughout.

Just need to know what to get exactly.

I'll tell the tranny guys to take the measurements you were asking for. In the meantime, waiting for David (gmtranny) to get back to me with more info.


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[CaseyS]

If this were that easy, everyone would have done it by now.

So I saw the servo out in the pics so I assume that work is done. Did you get the sun shell changed as well? Now you can see what I mean its the next part in the case after you pull the input drum.

So in summary, minimum parts required to convert an 09 (so far)

Bellhousing
Input drum with reluctor
Torque converter
Stator support

Keep at it. Anyone that thinks a swap is a week project like you see on TV and that you can forsee all the little traps and have every single part pre-ordered needs to have their head examined.

 

[humvee]

Haha.. True.

The wait is long, but I'm not in a hurry anymore. Don't want to build a kit car, stuck in the garage every other week.
Gotta do this right, I'm just grateful I have your input throughout.

Thanks C


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[cbetts]

That pic brings back memories fighting the alignment of clutch packs. I have spent some late nights doing the "jiggle" to get the last clutch to engage on a TH350. After two hours and some sore arms, I finally got the last one in, I picked up the front pump from the bench only to find that goofy c-clip looking thing that goes in with the first pack by the tail. Had to pull everything back out just for that!

Good times!

 

[humvee]

I have spent some late nights doing the "jiggle"

And there's our quote of the day!

 

[humvee]

.BSo in summary, minimum parts required to convert an 09 (so far)

Bellhousing
Input drum with reluctor
Torque converter
Stator support

So david from gmtrannyparts just came back with thes:

"Ok I think my research has lead me to conclude that the input drum you received from us along with the torque converter from the 5.3L engine (or a new one meant for a 5.3L) and a pump/pump stator tube meant for a 5.3L (and 5.3L bell housing) would work in your hummer. If you are comfortable pressing out the stator tube and putting the correct one in I can send you one."

@Casey, thoughts?

 

[CaseyS]

I think I agree. Make sure you get one that is made for ISS models. Also make sure it comes loaded with front and rear shaft bushings. I'm pretty sure you will be able to press the shaft out without having to disassemble the pump.

Hopefully parts can get there by the time you get back from your trip.

Have you checked the takeups yet on the converter?

Also to verify your bell housing should be right at 7" deep and have a triangle shaped top with a bolt hole at the top of the triangle. I think I verified that at the beginning of your thread.

 

[humvee]

After much research, David agrees that the stator shaft I need is A74529E (post 17) to fit the 300mm converter.

Can't get the tranny guy to measure anything from here. Going to but this stator. They installed the teflon rings on either side of it too.

More news soon.
Thank you C


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[humvee]

I think I agree. Make sure you get one that is made for ISS models.

After much research, David agrees that the stator shaft I need is A74529E (post 17) to fit the 300mm converter. Like you said.

Can't get the tranny guy to measure anything from here. Going to but this stator. They installed the teflon rings on either side of it too.

Tranny guy confirmed the bell housing is the one, has the extra bold and its off a 5.3 too.

 

[CaseyS]

To clarify, the Teflon orings go on the input shaft, you have those already. The stator support shaft that you are ordering has a brass bushing pressed into either end of it that becomes the bearing surface for the input shaft spinning inside.

 

[humvee]

The stator support shaft that you are ordering has a brass bushing pressed into either end of it that becomes the bearing surface for the input shaft spinning inside.

The input drum they sent already has the 4 teflons installed that will ride inside the stator tube. The stator tube will have 2 teflons and 2 bushings already installed in it and then the pump to torque converter seal will also be coming with it.

 

[humvee]

So, 2 weeks or so ago.. My tranny guy fell off a boat doing service on deck, broke 4 ribs and his collar bone. He's back to work today.

We pressed out the stator and installed the new one. Will send this out to Sam tomorrow.

Here's the difference before we pressed the i5 stator out of the pump.

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[humvee]

Which transmission filter should we use here. We lost the one we removed and they say there are two types, it depends on the crank case.

1/2 metal or full plastic..


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[CaseyS]

The filter is hummer application specific and the only ones I have ever seen were all plastic cases.

 

[humvee]

And you are correct.

I'm just wondering what i'll do when some of these Hummer specific parts become extinct.. I keep saying I'll hold on to my 3 forever, but at some point it'll become impossible.

Anyhow got a week of back to back filming scheduled.. Sam will try and finish it off now that its all there.


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[humvee]

some snaps of the tranny before it goes in. Anyone see anything out of the ordinary?

These cracks in the used bell housing I got are worrying me.

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[5gn-h3t]

Unless I'm missing something, I think you are just looking at marks from the casting process.

 

[JPaul]

That's what I am seeing as well. They are likely just cracks due to shrinkage when the aluminum was cooling after being cast. It shouldn't be anything to worry about.

 

[humvee]

Super! Mechanic is understaffed, so work is very very slow on the truck at the moment.
They installed the Alternator bracket and pulley I struggled with for so long. Here's whats left.

-Install tranny
-Fabricate exhaust downpipes, include cat converters and O2 sensors
-complete Harness installation
-Battery
-Airbox
-Rest of engine bay connections and components
-Fabricate new AC lines
-Extend Fuel lines
-Reflash ECU

... Fire it up

 

[CaseyS]

Cat converters? Didn't those get tossed out with the old engine?

I agree on the casting marks on the bell housing. Nothing to worry about.

The way you state that list you make it sound so short. Seems like all you have left now is finishing!

Don't forget to put a quart of fluid in the torque converter before installing it.

 

[humvee]

The way you state that list you make it sound so short. Seems like all you have left now is finishing!

Don't forget to put a quart of fluid in the torque converter before installing it.

Yeah, I don't want to speak too soon again, but apart from the AC lines and down pipe fabrication its all plug and play from here.
My i5 had one cat down the pipe, I still have it. The other was in the manifold.
Got 2 brand new cats made for a merc CLK, good deal.

I'll be sure to remind them of the fluid, it had totally slipped my mind.

 

[humvee]

Honestly I'm eager to hear what it'll sound like on the i5 resonator and muffler + 2 cats made for a German car. Hope its not too loud.
I removed the borla catback last year after the traffic department sent me an impound notice.


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[humvee]

So! Yesterday, nothing could wife the smile off my face.

Engine bay populated, and tranny bolted right up.
Had to buy a new starter, and ended up getting new AC lines. Heater hose was out of stock so I'll either get that online, or completely forget about it. Never used it its like 5000 degrees out here, and winters are mild.

Now for the tuning, Jamie had reflashed my PCM/TCM to take a V8 tune.
I have TWO V8 tunes at my disposal.
1) Stock V8 tune provided by Jamie, said it should load right up.
2) Fine tuned file for the V8 currently in my truck.

Both tunes are for the alpha, so I need to do the following:

a) reflect 4.10 to 4.56 ratio change.
b) remove O2 codes caused by the rear O2 sensor delete
c) Reconfigure fan settings. I have 2 fans and one relay for them. I can wire them to work as one but would still need to remove codes and set temperature parameters.
d) after factory flash I'll need to learn the crank angle , otherwise a po315 code will come up.

A and B are straight forward, I'll be researching the whole compare/copy option. BUT I do not know what C and D are all about.

Fun fact: Buying an Alpha, rebuilding the tranny and rehearing to 4.56 would have been cheaper by $3,000. Not complaining, just saying.

 

[CaseyS]

Congrats. You are in an elite club.

Looking forward to a first drive report. So does this mean you have cranked it? Not to discourage but obviously there will be some debugging involved to get it going.