Allenfab’s 2008 5-lug SAS and LS swap

And if they are semi-seized in there with crud and rust like every other leaf spring bolt that's been off road, what will you do then? I'm just looking at it from my maintenance perspective (you know, the one we all have when we curse engineers and say that if the engineer that designed this had to work on it, it would be designed completely different), and trying to make suggestions to save some headaches at a later date. Better to assume that nothing is coming out easy after a few years of being subjected to dirt and water.

 

I mean sure if you play in mud all the time and don’t clean it after like most people that have that issue. Plus a plasma cutter makes quick work to put a hole on the other side if it comes down to it.

 

stick a pry bar in there an pry it outward, or stick an impact on the bolt head and reverse it all the way out.... that's the way that I have always done it *if* they don't just slide out. Or like Tim said just zip a hole on the inside with a plasma if it ever comes down to it. I'm certainly not worried about it.

 

Okie-doki. Was just a suggestion.

 

Went ahead and removed all unnecessary plugs and wires from the engine bay that won't be needed any longer. This pile is JUST the ABS and air injection pump wiring



New loom and tape on everything. All wires were either terminated/unpinned where they went into the cab and into the plugs behind the driver side kick panel or inside the fuse box in the engine bay. I wanted no cut/loose wires exposed. It was time consuming but will be worth it in the end for an overall cleaner install.

 

Glad this part is done

 

Wow, that's an impressive amount of space in there. It almost looks like you could have gotten away without cutting the core support if you went with electric fans.

 

The only reason I had to cut it in the first place was to get the old motor out and the new motor in, guess I should have bought a 2-ton hoist .

I will still however be going with electric fans. They will be plug and play with the engine harness I’m getting

 

Convince me that I should have an offroad front bumper instead of running the stock one with the winch cutout

 

No, I like it!

 

Only if you put a big chrome Westin bull bar on it for 30% more Bro.

 

Few small updates. Whipped up some sliders... decided to go a little lighter duty than what I previously had so its all 1.25" sch40 that I had from another job (pretty much all my metal is from one). I had to remake the core support mounts and threw in some poly bushings while I was at it. Finally, I got the Borgeson steering stuff in and mocked up. I need to get a 1" heim to make a support for the 1" DD section of the shaft to go in.

 

Steering shaft has been a nightmare for me. I ordered joints from Borgeson per a couple builds on the web, but the upper joint, the 5/8” 36 spline joint, just barely didn’t fit. I had to individually file deeper grooves into the stock splined shaft coming from the steering column to get it to fit. No pics of that headache, but I did remove the factory rag joint under the dash since my new shaft is collapsible. I also ordered a 1” self-centering pillow block style bearing that will be used to support the steering shaft to remove wobble. I just have to build the driver side shock hoop first to mount it off of that…



In the mean time, I did get some Amazon basics special sound deadener applied in the cab on both the back wall and the floor. This truck will be getting a drop-in vinyl floor instead of a sprayed on liner like my old truck because I didn’t care for the heat or the noise the last time. I’ll finish the sound deadener on the trans tunnel once it’s cut up and modified for t-case and transmission shifter.



I was also able to get some new steel wheels from 4 wheel parts that were on sale for $92 a piece. I wanted aluminum wheels this time but I can’t beat cheap stuff that will do the same job. Apparently those are now back ordered even though they showed in stock when purchased so not sure when those will be here

 

I remember the steering shaft on my truck bringing the suck as well, also using borgenson parts. Probably no real fault of them, just interwebs parts recommendations.

 

My first gen was actually super easy, the 95’s have a DD shaft coming from the steering wheel so just a joint with two DD ends and viola, it’s done. Also no need for a support bearing either. But, one of those things that once it’s done…. It’ll be done forever

 

Shock towers and steering shaft support done. I bent up a couple hoops but didn't like how they would look, and building a mount for that bearing off of the driver one just wouldn't look good. Shock tabs will be welded in later, but needed this one so I can move on down the steering. Next up, rebuilding the steering box and drilling/tapping it for hydro-assist.

 

Motor mounts turned out nice.

 

Same to you