Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

Hey guys, bought this truck last May. Factory 454 TBI with TH400 truck. Camper Deluxe, power windows/locks, etc. Previous owner had the truck converted to a NV4500 5 Speed (1993 version with the ultra low 1st gear). He also c-notched, air bagged, axle flipped and boxed the entire frame from the cab to the rear bumper, installed a custom gooseneck hitch tied into the frame, converted to rear disc brakes on the Dana 70HD, had the seats recovered, new suede headliner, new carpet, dynomat everything, and recovered the dash pad.

The only major mods I have done is the Dakota Digital VHX gauges.

The original truck had Thorley Tri-Y ceramic coated headers, Edelbrock TBI intake, TB spacer, and custom chip. It did okay on mileage, 14 hwy, 10 city, 9 towing. But I think I can get a bit better mpg with the 6.0.

The original plan was 6BT or a Duramax. Both were scrapped after I found out my early NV4500 couldn't 't be made to work with either.

The next plan was a 5.3, mild cam, with a GT45 turbo.

Last month I stumbled on a cheap LQ4 6.0 from 2500 Van with low miles and bought it. Same basic plan, the cam is a super mild truck grind, Summit 8719. I pulled the heads for inspection, all good after some BTR valve springs. One minor issue is a couple spark plug threads were goobered, so I needed to chase the threads to clean them up before getting bolted onto the block. Went with BTR LS9 head gaskets and bolts. Going to be a low boost setup, so the extra cost of head studs isn't warranted. LS7 lifters and trays are installed, replaced the timing chain with a LS2 replacement.

Using a set of stock truck injectors that have been decapped and flowed. Stock truck intake manifold, return style rails, stock TB, Amazon cast stainless turbo manifold (after a **** ton of flash and spark plug boot clearancing), ebay 31x12x3" core intercooler (painted satin black), etc.

Went with Hooker C10 LS mounting plates with polyurethane mounts. The reason I went with the Hooker plates is because after some trimming, they allowed me to retain a factory style AC compressor. I scored a Denso 10S20F style from a Tahoe/Burb that had factory rear air. The theory is the larger of the two truck compressors will move enough refrigerant to keep the old school R12 A6 system happy. I already have a modern style bar and plate AC condenser up front. The reason I wanted to use the factory compressor is because the turbo manifold is sitting about where an aftermarket bracket would sit to mount a popular Sanden 508/709 compressor.


A bit of progress. Got the 454 pulled and sold on Monday. Got the NV4500 mated to the LQ4 yesterday and dropped into the truck.

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

Nice progress!

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

:agree:

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

A bit closer...

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

The truck looks great, it sounds like the previous owner went the extra mile on upgrading the truck.

I am not overly knowledgeable about the 6BT swaps and you mentioned the NV4500 was an earlier version, however I thought the NV4500s were the transmissions for the 6BTs?

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

6BT didn't get the NV4500 until 1994. Before that they had the weaker Getrag.

The '92-'94 GM NV4500 version had a different input shaft that does not interchange with the later case and a different bellhousing to case bolt pattern. '95+ GM NV4500 versions would interchange and work with a 6BT 1994+ NV4500 version with a bellhousing and input shaft swap.

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

Thanks for the information. Looking forward to watching your build.

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

Getting down to the little things...

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

More misc pics of the truck...

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

that's a really nice dually...swap looks great..!!

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

really cool!! nice motor swap. I was wondering what you have planned or did related to the wiring of the motor to the original truck wiring?:ito: I am trying to figure out the ways to connect my wiring on my swap...

I like the interior color:metal:

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

I started with a 2001 Suburban harness that was converted to stand alone operation by Jim's Performance. I haven't begun removing the TBI harness yet. I will get it sorted after the LS swap is done and no troubles.

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

ok, I am "trying" to use the original uncut harness that I received with the engine ('13 4.8) maybe I might look/contact your guy???
do you have contact info for jim's performance? web page or ???

thanks for the replies..

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

I didn't have him do the stand alone harness, I bought it already done.

Google is your friend as far as finding his contact/website.

There are any number of folks that can do a harnes. I previously used Warr Performance in the past and their work is top notch as well.

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

Swap done, runs and drives. Tuning is a slow process. More pics:

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

Looks good!!

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

Thanks!!


Amador County, eh? Sounds familiar.

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

Has a ring to it, huh!! ;)
We are closer to Ione...
If I see you and your truck, I'll say Hi.

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

Dyno/tune time.

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

Question-How are you running this setup in CA? Dig the truck!

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

Very cool and clean swap. Great looking rig.

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

What were your numbers?

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

No annual/biannual smog testing in Amador County.

Thx dude.

I appreciate it!!

495HP/550TQ at 7 psi. Timing is set at an ultra conservative at 14-15* total timing while in boost. Wasn't after big numbers, just wanted a reliable daily and tow pig.

Although as of late, I only driver her when towing a couple of times a year and on the weekends occasionally.

Even though I get 16 mpg since the swap, I bought an old mk4 TDI Jetta for my new job that is a 50 mile commute each way, M-F.

Cummins Time....
 

Unfortunately the truck gets pretty warm with towing a grade with any amount of boost. So ended up buying a 6BT Cummins and NV4500HD for it. Planning on dropping it all in by the end of the month.

Re: Squarebody Crew Cab Dually 6.0/Turbo/NV4500 Build Project
 

Wouldnt upgrading the cooling system be a bit more economical?