GEN IV (AFM, flex fuel) into '97 2dr 4wd Tahoe

[harascho]

Hi guys... some progress on my side in the past days.

I have the new 5.3 flex fuel / active fuel management in my Tahoe's engine bay...



I used the common adaptor plates to switch from the new 4 bolt to the older 3 bolt engine mount style.



I must admit the engine slipped into place with only a slight massage on the rubber mounts necessary.


yesterday I bolted the transfer case to the new 4L60E ( Why didn't I go for the 6L70 as Patrick did?? I really don't know..)


Then all is prepared to bolt the tranny to the engine.
I am curious of all lines up in the old positions, I will know in a few hours..



I also removed the dash. I have to modify the dash to accept the '07 instrument cluster.. I did a short testfit and I think I can do it in a way that the whole setup looks good.







A lot of the under dash wiring will be cut out and replaced by the '07 harness.
Lots of circuits are different now, cause in the '07 trucks the BCM controls most of the functions as exterior lights, turn signals ignition switch and the related power states of the truck. I built a small adaptor box in which I stuffed all the necessary circuits to adapt the '97 logic to the '07 logic, for example the headlights... in the OBS trucks the electric load is switched by the headlight switch (it switches 12V from a fused batt source to the lights..) lots of current flows over the switch contacts.. in '07 the headlight switch just grounds some BCM inputs and the BCM switches the correct relais in the engine compartment fuse box. Another benefit is the bulb fail management of this new setup... you will have a message in the instrument cluster when a bulb fails..

[harascho]

This time the exhaust was on my list:

y_pipe news...

I did some welding and pipe cutting yesterday... Why did nobody try to built a bigger y-pipe where the two pipes meet somewhere behind the transfer case?
In this way you will have access to the tranny pan. Only drawback is to remove the y-pipe you have to remove the tranny crossmember first. But how often do you remove a Y-pipe??










Only thing I had to do is to cut out two of the O2 sensor flanges and weld them behind the left and right cat.

This was yesterday late afternoon. It was not planned that after drilling the hole for the first o2 sensor, that the cat heatshield cut through my finger.... ok the doc in the hospital stitched all tohether...
But that will mean electric wiring for this week... no heavy parts or wrenching....

[NITROUS]

Looks great! Keep us updated, this is a nice project...................