1/2 Ton 24v Swap/build

Got a good bit done this weekend. Wired up all the guages, painted the turbos again, installed 12v tappet cover as well as a venturi for the PCV system in the downpipe which required removal of the fuel pump. Installed the hydro boost with new lines and wired the Airdog and fans.

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12v Tappet cover with PCV port.
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Had the exhaust cut down today. Going with a turn down under the bed for now.
 
Got to drive the truck for the first time on Sunday and have a few observations.

1. It still leaks oil even with new front cover and front main. In fact, it continued to leak oil over the few months the motor was out of the truck and in the shop after I drained the oil during removal.

2. It drives like an undersprung wheelbarrow with 1400lb/ft trying to get to the front.

3. EGTs are MUCH lower now. Either something with the fuel system is different or its not having to work as hard to drag the 1/2t chassis around. When I first started it, I thought the egt guage was broken. It was on the low peg at idle (100 F) and only gets up to 300F at cruising speeds. I think it needs more fuel from the Airdog. Its at about 27psi right now measured at the T in the fuel feed.

4. The truck seems to have 4.10 rear end gears. I thought it wouldve been 3.55s but the rpms/speed are exactly the same as the 1t truck. What are my options for gear sets for the 9.25?

5. Nozzles on diesel filling pumps at gas stations are larger than gasoline filler neck inlets. Screw driver required to hold the flap open.

6. All the electronics on the truck still work, which I am very pleased with.

7. The right rear tire doesnt stand a chance at any speed.

8. I dialed the fuel back 6 turns on the adjustable fuel plate. It still smokes a lot and still makes good power. Im thinking of ditching the adj fuel plate for a factory pressure referenced AFC and some different delivery valves in the pump to try and clean it up at low boost.


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Batteries in the tool box. Turned out ok.
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I think I am going to get some 3/4ton front springs and maybe some van LCAs or just cut the springs. It also needs shocks in the front. Any ideas for lowering the rear? Im not super excited about an axle flip but I dont think just shackles will get it low enough. Thoughts?

Id also like to go with some 17s or 18s since the stockers need new tires anyways. I dont want to shell out the cash for 20s I dont think.
 
Looking good!

I think the junkyard may have been bama parts. Its up past UNA on 231/431 north right when the highway makes an S turn. There are a couple old ram vans and 2nd gens in the junkyard on 36 as well. The highway 36 junkyard has a couple good old boys that usually give me good deals on the 1st gen parts I need.
 
Thanks I will check them out. Truck received daily transportation duty all this week.
 
After reading your thread I think I may have gone too small with fuel lines. I ran 3/8 from the tank to the pump
 
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Bought some 2009 4wd wheels and tires this weekend. Ran into an issue fitting the fronts. The wheel bearing housing is too big for the bore of the wheels. Backs fit great. I may have to go to some 2001 spindles with sealed bearings in order to use the fronts.
 
Timbeaux38 said:
Have you driven it in the rain yet?
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It rained while I was at work one day last week, so I had to drive home on wet roads. With the other tires, it would barely get out of the sealed parking lot! haha. The tires on the new rears are much better. It hooks in 5th gear now with the fuel dialed out.
 
That looks like fun, nice work! I'd just grind the centers out for the front wheels. Or if you know someone that could machine them.
 
Knoberman said:
That looks like fun, nice work! I'd just grind the centers out for the front wheels. Or if you know someone that could machine them.
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I could have them machined for a few dollars each. Im not sure if it would look odd with the axle cap protruding from the center though. As long as I painted them black I guess it would be ok. Maybe paint the wheels black as well so it would be less noticeable?
 
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F8L GTO said:
I think I am going to get some 3/4ton front springs and maybe some van LCAs or just cut the springs. It also needs shocks in the front. Any ideas for lowering the rear? Im not super excited about an axle flip but I dont think just shackles will get it low enough. Thoughts?
Click to expand...

Whats the deal on van control arms? Lower spring mount than the trucks?

As far as the gearing in the 9.25s, I the diff I just threw out had 3.23 or 3.27 gears in it. It was a bare bones '96 V6 5 spd truck.
 
Tate said:
Whats the deal on van control arms? Lower spring mount than the trucks?

As far as the gearing in the 9.25s, I the diff I just threw out had 3.23 or 3.27 gears in it. It was a bare bones '96 V6 5 spd truck.
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Thats good to know. I will be hunting that ratio then. The van LCAs have spring "buckets" good for an inch or two in drop supposedly. I have not done it personally but I have read it on the internet which means its 100% true right?
 
I have the exact same wheels on my half ton. The fronts just have wheel spacers on them to clear the hubs. Mine are also painted black. If you would like I could snap some pics for ya.
 
91shelbydaytona said:
I have the exact same wheels on my half ton. The fronts just have wheel spacers on them to clear the hubs. Mine are also painted black. If you would like I could snap some pics for ya.
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That would be awesome. May be picking up a set of 1.5" spacers tonight.

Noticed your sig. I was also going to look at a 2000 Jetta tdi tmrw. Similar tastes I guess.
 
Found some spacers for sale locally. 1.5" all the way around. The fronts poke a little bit and the pass side hits the fender liner, which is easy to fix. Now for some stiffer springs in the front to eliminate the bounce.

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The next thing to work on is the smoke. It has full cut DVs and an adjustable fuel plate. I have the fuel plate set just a touch over half travel and it still smokes a lot and feels like its bogging with alot of throttle input at low rpm. Runs alot better if I gradually increase throttle input as the rpms climb. Any suggestions on what to swap first?
 
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