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Couple of questions?
1) the vapor purge valve on front of intake can we get rid of this or is it something needed? If I do keep it does it tie in to the return fuel line?
2) My truck is extended cab and the truck I got my engine out of was a extended cab also. But I've measure the transmissions and the 03 tranmission is 1" longer than the older one. If my driveshaft won't fit would it work if I just switch the tailhousings from the older 96 to the newer 03?
You can use your existing 4l60e if you want.
Use these parts
If you want to install a GEn 3/4 engine in a 96-99 truck you can use the existing 4l60e by using this flexplate spacer
http://www.crateenginedepot.com/store/LS1-Flexplate-Spacer-12563532-P1343C0.aspx
and 6 of these longer bolts
http://www.crateenginedepot.com/store/LS1-Flexplate-Spacer-Bolt-12563533-P1344C0.aspx
With this flexplate from a GEn 3/4 truck that used a 4l80e trans
http://www.crateenginedepot.com/store/LS1-Flexplate-12551367-P1342C0.aspx
I would think that your existing driveshaft should work with the newer 5.3/60e combo.
And no swapping tailstocks will not make any difference as its the outputshaft itself that will need to be swapped.
Your 1996 trans is a 4l60e with a non removable bellhousing and stamped steel inspection pan. In late 1997 GM started using a bolt on bellhousing 60e case that surrounds the TCC 360° nad has a small 3" cover to attach the TC bolts. This case is very similar to the 60e's that are used behind the GEN 3/4 engines.
I really dont think you will have any fitment problems with your driveshaft. Perhaps the 5.3 sits slightly more towards the rear of teh truck than the 350 does?
You'll be able to tell once you get the engine in place.
Goodluck
peace
Hog
Plug the line at the canister with a vacuum cap and you'll have to delete the purge solenoid DTC's out of the PCM. The 03 should fit fine, you might have to move the transmission crossmember up a hole on the passenger side.
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