Build Thread - 1-ton Chevy Swap

JohnnyU · May 13, 2008

I'm fairly certrain that most of you guys won't be interested in this project since it's not a Ranger

. I reserve the right to remove any posts that are made in an effort to start an argument or otherwise add no value to this thread. This will highlight the build process of the truck that is replacing my Ranger as far as wheeling duties are concerned. The truck is a 1991 Chevy 1/2 ton. I bought the truck shortly after my 16th birthday. I plowed snow with it, pulled trailers, and DD'ed it until last May. It had the solid body and frame, good v-8 and built auto trans that the Ranger only dreamed of, so it was deemed as a better platform to continue building from.

I got an awesome deal (free) on a 14FF rear axle from a 1-ton dually.

Tore it down and did some cleaning/rebuilding:

MMM, full floating axle shafts.... Ø1.458" at the flange, Ø1.351" operating

I decided the drums had to go, so I swapped on some disc brakes using caliper brackets from Ballistic.

I bought a pair of diff covers (one for the front Kingpin 60 as well) from GreatLakeOffroad - Awesome Product!

All cleaned up, painted and reassembled.

I also welded the tubes to prevent them from inadvertently spinning under high-torque conditions. It's a common problem as the plug welds the factory uses are really not sufficient.

This is as far as I've made it to this point. I've got most of the parts to proceed, I will be rebuilding the front 60 as well as installing the new rear springs and shackle flip kit. Stay tuned for more progress.

Dangeranger3 · May 13, 2008

FINALLY! I've been waiting for this build. All the work looks good as usual. What gears do they have? Locker maybe or what the hell is that in the diff?

gotmudd · May 13, 2008

only got one word and a smiley: NICE :drool:

, oh yeah, and one comment, AS LONG AS YOU'RE HAPPY :yahoo:

, who cares what other people say, i say way to go. and one question how hard was the disk brake conversion, i have drums front and back and want to covert to disks up front :drool:

Mutant Pony · May 13, 2008

I don't care if you want to deal with crap.
Posting it here is just asking for a fight, As usual.

JohnnyU · May 13, 2008

Dangeranger3 said:
FINALLY! I've been waiting for this build. All the work looks good as usual. What gears do they have? Locker maybe or what the hell is that in the diff?

The axles both have 4.10's in them now. Not great, but it's better than 3.55's or anything less. My plan for now is to run them as-is just to get them under the truck. Once I have the truck rolling on the new axles and the suspension dialed in, I can start thinking about regearing. The 14FF has an open carrier but uses the "orb" method for a locker. Basically, the four spiders and the side gears were welded into a ball or "orb of traction" as seen here:

This picture is from biggervalves as I didn't take any pictures when I welded mine up.

gotmudd said:
only got one word and a smiley: NICE, oh yeah, and one comment, AS LONG AS YOU'RE HAPPY, who cares what other people say, i say way to go. and one question how hard was the disk brake conversion, i have drums front and back and want to covert to disks up front

The disc conversion was simple, its essentially all bolt on parts. You will need to do some modification to your brake hydraulic system to make them work properly, but that will be covered later. Check out Pirate's tech section for more information on brake swaps. Billavista has done a GREAT job with those articles.

Jspafford · May 13, 2008

Mutant Pony said:
I don't care if you want to deal with crap.
Posting it here is just asking for a fight, As usual.

What do you mean by this?

I am anxious to see what the outcome looks like John.

mhughes165 · May 13, 2008

JohnnyU said:
The axles both have 4.10's in them now. Not great, but it's better than 3.55's or anything less. My plan for now is to run them as-is just to get them under the truck. Once I have the truck rolling on the new axles and the suspension dialed in, I can start thinking about regearing. The 14FF has an open carrier but uses the "orb" method for a locker. Basically, the four spiders and the side gears were welded into a ball or "orb of traction" as seen here:

This picture is from biggervalves as I didn't take any pictures when I welded mine up.

The disc conversion was simple, its essentially all bolt on parts. You will need to do some modification to your brake hydraulic system to make them work properly, but that will be covered later. Check out Pirate's tech section for more information on brake swaps. Billavista has done a GREAT job with those articles.

the 4.10's should be plenty for most needs, i know guys runnin 38's + with 4.10's, and if u were to drop a sm465 into her, witha 205 case, then u would have a mean granny gear in it, and then ud have a pretty much bullet proof drivetrain for trucks under 40's, im a equal oppritunity offender, i build everything, aslong as it wheels it dont matter to me

Maverick · May 13, 2008

I was wondering if you were gonna post a build for that truck here. Depending on how big of a tire you go, 4.10's wouldnt be bad if you had a doubler. Speaking of that, what are you gonna run for a t-case(s)?

JFA_Spyderman · May 13, 2008

Looking Good! I am excited to follow along. :icon_thumby:

Bray D · May 14, 2008

excellent, I was gonna ask you when you were gonna start working on that baby. do you have any deadlines/dates for completion?

zainyD] · May 15, 2008

1 tons are ALWAYS nice!

koda6966 · May 15, 2008

JohnnyU said:
I'm fairly certrain that most of you guys won't be interested in this project since it's not a Ranger . I reserve the right to remove any posts that are made in an effort to start an argument or otherwise add no value to this thread.

I had a few posts about my '78 3/4 ton on here, no one really argued much.

I'll be checking this posts for updates on the build, it sounds interesting.

JohnnyU · May 15, 2008

Got the truck into the garage last night, started tearing it down this evening when I got home from work. Tonight I got the old rear axle pulled as well as the springs. I just need to remove the rivets that hold the shackle hangers to the frame. Then i can clean up the frame, shoot it with some paint and install the flipped hangers and new springs.

Got some stuff from Ballistic Fab.

Out with the old: the ol' 10-bolt.

Driver side spring out, passenger spring hanging by the shackle. (yes, the truck has developed the typical rear wheel well rot)

I'm planning on the new poly spring bushings being here tomorrow afternoon. If they make it, then I'll be able to put the springs in and get the 14FF bolted up. After that all I'll have to do is replace the ujoint in the drive shaft and plumb the brake lines back along the frame. Then, onto front end disassembly.

Kona · May 16, 2008

Nice rear bumper.

95XL · May 16, 2008

Nice rear bumper.

+1

Build Thread - 1-ton Chevy Swap

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