2nd Gen compatibility in 1st Gen trucks

[dpuckett]

This idea was given to me by another member here, who exactly it was escapes my feeble mind at the moment. Anyway, there were quite a few changes to the engines and trucks from their introduction in 1989 till the end of the 2nd Gen run in 2002. A lot of things were upgraded, some are a direct fit into our older trucks, some require mild to extensive modification to make it fit. Seeing as we, as a group, are fairly fearless and adventuresome in our quest to make this or that better for our old rigs, or due to the scarcisty of aftermarket stuff for our trucks, I thought I'd start a list of stuff that will fit, based on my own experience and readings here.

Turbo- direct bolt on to the engine. If the exhaust housing of the "new" turbo is wastegated, the downpipe will have to be either shortened or moved back about an inch and a hair. If you lack the heatshield of the intercooled trucks, I would highly suggest cutting the DP after the turbo clamp flange and again right where it fares to 3", and reweld the flange to the DP,taking a total of an inch and a half or so off. ALso, if you are putting a HX35 or HY35 turbo on a nonIC truck, you will need to get or make a bigger intake hose from the filter, and rig up a way to plumb it into the intake. Take a look in my reader's rigs for pics of the HX35 install.

Head- from my reading, direct bolt on. Some have said flow is improved slightly over the older stock heads. I have no hard evidence (from a flow meter) to refute or back this claim. Some accessories (t-stat housing, intake, heater hose routing) require some creative thinking.

Exhaust manifold- direct bolt on from 12v; 24v manifold will not work. The ports are different.

Clutch- The stock clutch and flywheel from your Getrag will work with a NV4500, provided the NV4500 has the stock 1-1/4" input shaft. You should research into whether you can use the flywheel adaptor and starter. Bellhousing is different I know.

Intercooler- Will fit with some modifications to the radiator core support, and new piping/ boots, as the 2nd Gen cooler is a bit wider than the stock 91-93 IC, it can work. Some have put the newer style ones in upside down and had a good fit.

Front 40-20-40 split bench seats- requires an adaptor to be made to bolt it to the floor. I'll look up the thread and post a link here for specifics.

Radio- For AM/FM CD or CD/ cassette, I have been told it is a direct bolt in, plug and go fit. Dont know for sure; will find out as soon as I get the cash. I miss being able to play Chris LeDoux and Toby Keith when I want to.

Someone else chime in here with what is required for axle (D80), auto tranny, and any other swaps you can think of.

Daniel

edit: in addition to the above I'd like to add the following...

Injector lines, along with injector bodies- and possibly tips- along with pop off readjustments for the higher pressures the P7100 runs. Timing gear housing needs changing, which involves removing the cam (which, in turn, basically means take off the grille and everything behind it to get to the cam), and the rest of the gears in the case. The P7100 takes a different pump gear than the VE, as well. I've read that you can run into interference with the brake master cylinder from the AFC housing on the P7100. It looks like you might also have to change the intake horn and related plumbing. It might be doable IF you do your own work, and can get a great deal on parts. Otherwise, get a 2nd Gen engine, drop it in there, and sell the VE pumped engine as a used take out to help offset the cost.

Daniel