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Thread: 90 GMC C3500 dually 6.0 4L80E swap in Frankentruck!

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  1. #1
    Join Date
    Feb 2012
    Posts
    274
    Damn that suck someone broke into your truck, glad to see your putting it back together in a good way.

  2. #2
    Quote Originally Posted by canada4g63 View Post
    Damn that suck someone broke into your truck, glad to see your putting it back together in a good way.
    Wish it was just broken into. They stole the whole truck! There's allot I didn't get back so unfortunately I'm going to have to repaint. Was a new paint job too!!

  3. #3
    didn't get it to the shop yet, going to get on that in the morning, I did get a few hours in tonight. I took out the old 90' brake pedal assembly seen here.


    then was able to get the 95 assembly in and welded into place.
    we drilled the welds out and welded the new setup in.
    this is it before welding it in.



    after that I was able to get the 05 column into place. fit perfect!



    tomorrow is the big day, will get it up on the lift and get the tank swapped and start hooking everything up!

  4. #4
    Got some time to work on the truck today. I got the yoke on the driveline, and it was the perfect length, no modification (besides yoke) needed.


    so we went ahead and got her up on the lift and mounted into place.



    then good ol' Murphy jumped up and bit me!
    everything was going great! I knew it was tooooo easy up till this point.
    time for the fuel tank, got the old one out.....


    went ahead and started to test fit the Van tank into place, looked real good at first then noticed a section of the frame just wouldn't let it go in. so down it came, not going to work.



    so now I'm trying to retrofit the pump from the van into the truck tank. not sure if im going to go that route yet. took the pumps and sending units out of both and will play around with some other configurations.. here is the van pump disassembled.


    am going to look into maybe a late model gm dually tank or a shorter van wheelbase tank..my main goal is to retain the fuel gauge with the 05 cluster so I need that sending unit in the tank. need a day to think over how I am going to tackle it, Suggestions would be awesome!! shop closed early tonight for new years so I started playing around with my new grill ornament design pretty sure im going to use this..



    this is my 3D prototype machine, pretty fun, can print damn near anything in ABS plastic. going to come in handy for a few more custom parts im going to make for the interior and making brackets to retrofit all the 05 stuff.

    anyway, Happy New year everyone, will be back on it on Thursday going to take tomorrow off.

  5. #5
    Join Date
    Mar 2013
    Location
    Long Beach California
    Posts
    637
    why exactly are you trying to swap tanks/ sending units??? the pumps themselves are direct swaps utilizing the stock units.... i have a 95 and all i did was change the pump to a delco 381. straight forward.. unless your in cali and doing a legal swap like i did then there is more involved which i can try and help with but idk your loacation... just saying there is no need to swap the full unit out.... just the pump itself will be fine to get the pressure you need...
    Like Tumbler in "Gone in 60" I'll drive anything with wheels or without

    My 95 ECSB LQ9 build thread - http://www.ls1truck.com/forums/lsx-t...to-95-obs.html
    CALI LEGAL ENGINE SWAP!
    Stock 03 LQ9, DBW, 95' 4l80e w/ Transgo shift kit, 2010 50# GM injectors, 2800 Circle D stall, Spectre CAI, Upgraded trans cooler, Home-made E-fans/shroud, Dual EP-381 fuel pumps w/Home-made hotwire kit
    NEXT ON LIST: Dual Battery setup, CAM/Valvetrain upgrade, Build my own rear mount turbo, TRU-TRAC, HIT THE STRIP!!!

  6. #6
    Quote Originally Posted by kewljay223 View Post
    why exactly are you trying to swap tanks/ sending units??? the pumps themselves are direct swaps utilizing the stock units.... i have a 95 and all i did was change the pump to a delco 381. straight forward.. unless your in cali and doing a legal swap like i did then there is more involved which i can try and help with but idk your loacation... just saying there is no need to swap the full unit out.... just the pump itself will be fine to get the pressure you need...
    Were you able to put the delco 381 in the old pump hanger?
    That sounds like my best option right now without going external.
    If I can put the. 381 in place of the 90 pump I would just ad the sending unit to the old hanger?
    Does that make sense?
    I'm in Las Vegas by the way but for emissions I only need the tailpipe probe and a good gas cap. No obdii on a 90 so they won't have to check the computer when I smog it. Which is coming up soon. Forgot about that.
    Last edited by JunkYardPirate; 01-02-2014 at 03:07 AM.

  7. #7
    Join Date
    Mar 2013
    Location
    Long Beach California
    Posts
    637
    Quote Originally Posted by JunkYardPirate View Post
    Were you able to put the delco 381 in the old pump hanger?
    That sounds like my best option right now without going external.
    If I can put the. 381 in place of the 90 pump I would just ad the sending unit to the old hanger?
    Does that make sense?
    I'm in Las Vegas by the way but for emissions I only need the tailpipe probe and a good gas cap. No obdii on a 90 so they won't have to check the computer when I smog it. Which is coming up soon. Forgot about that.
    ok hold on. your truck is a 90 but your putting a 95 dash... im assuming this means DASHBOARD. but your putting an 05 gauge cluster in. is this correct? I think I'm following now... lol.

    well in that case you won't need the old style sending unit at all since it sends the signal in a different manner. in 96, that's when obd2 started and gm changed to the newer style. so your EASIEST option would be to find a tank from a 96 to 98 truck. the duallies kept the body style until 2000 iirc. any of those should have the newer style sending unit and the tank should fit right in there. not sure if the duallies had bigger tanks tho.... and that would be it. fuel pump AND sender solved. but a tank isn't exactly cheap.

    or you somehow remove the float wiper of the old unit and put the new wiper/float on. this would be the cheapest but would require some serious engineering! lol. and you would still need to swap the pump to the newer style also.

    OR like I mentioned, do like I did and make a bracket for the new float and install it inside somewhere. you could use the wires from the old one since u don't need it. that way you don't have to add wires to the tank and try to seal it. that was a pain in the ass...

    other than that, I can't think of any other way...

  8. #8
    Join Date
    Mar 2013
    Location
    Long Beach California
    Posts
    637
    k..my main goal is to retain the fuel gauge with the 05 cluster so I need that sending unit in the tank. need a day to think over how I am going to tackle it

    i guess i missed that... i think your gonna have to do what i did as you have two options. option one.... install newer style sending or tank with new sending unit like your trying to do along with a new gauge cluster for everything to work properly. the older gauges use a different resistance than the newer ones. plus the pcm supplies 5v to the sending unit rather than 12v.... option 2..... do like i did, keep the same tank, change fuel pump to the newer style, and add the sending unit to the tank.. not the whole thing... just the float part. i basically have two floats in my tank now. the original that uses 12v to keep the old gauge working like it should. and the new added one just so the pcm can see whhat the fuel level is at. if you do this though, you will need to add wires going into the tank...
    Like Tumbler in "Gone in 60" I'll drive anything with wheels or without

    My 95 ECSB LQ9 build thread - http://www.ls1truck.com/forums/lsx-t...to-95-obs.html
    CALI LEGAL ENGINE SWAP!
    Stock 03 LQ9, DBW, 95' 4l80e w/ Transgo shift kit, 2010 50# GM injectors, 2800 Circle D stall, Spectre CAI, Upgraded trans cooler, Home-made E-fans/shroud, Dual EP-381 fuel pumps w/Home-made hotwire kit
    NEXT ON LIST: Dual Battery setup, CAM/Valvetrain upgrade, Build my own rear mount turbo, TRU-TRAC, HIT THE STRIP!!!

  9. #9
    my truck is a 90 so the newer 95+ fuel pump assembly wont fit in it. I am thinking maybe a 99 truck tank might work. was worth a shot to get the 05 tank in there but that would have been too easy.
    I might just go with an inline fuel pump and just put the new sending unit into the tank so I can keep the 05 cluster fuel gauge working.
    im not keeping any of the 90 interior components at all. the column is 05, the dash is 95 the dash harness is 05 the AC blower is the only thing inside still 90.
    this is why its a Frankentruck! I am putting parts from many others into a 90 cab..

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