rollerlocked
Well-Known Member
- Messages
- 60
- Location
- Wendell, NC
questions I had entering this project
Q. Will I need a gantry crane to pull and place the engine. A. no, I was able to pull and place the engine by it self with the hood on with a cherry picker.
Q. Will the I5 4l60 work on the v8 engine A. no, the bellhousing is different as well as the shaft going into the bellhousing
Q. what headers will work out of the box A. none that i can find , but with minimal mods the doug thorleys will fit
Q. what do you do about wiring A. there are many wiring companys I went with a forum member " 04colyZQ8 "
Q. what does a performance shop charge to do the swap A. I was quoted 30-60 hours at 100$ an hour
-parts list-
12573337 filler cap
12593348 filler cap o ring
12612350 oil pan gasket
rear main seal
rear cover gasket
cbm rear cover alignment tool 40$
hp tuners 499- 649$
-fuel lines ???
custom power steering lines 100-150$
-transmission dipstick tube ???
starter 65$
a/c compressor 61$
alternator 50$
H3 alpha 4l60e 40k miles 900$
LH8 120k miles 1600$
H3 alpha PCM + TCU 150$
flexplate with bolts 50$
current performance engine mounts 175$
exhaust manifold gasket
coil pack
transmission fluid
transfer case fluid
oil filter
oil
exhaust stud kit 30$
15-33806 ac delco a/c lines a/c compressor to condensor 110$
15-34365 ac delco a/c lines firewall to a/c compressor 80$
15-31055 ac delco a/c seals x 2 for the factory i5 lines 2x6$
25844416 ac delco heater hose kit 140$
23436 "gates" upper radiator hose 40$
23437 "gates" lower radiator hose 40$
dacco B85TMBX torque convertor 170$
89009 "dayco" idler pulley 20$
current performance motor mounts 163$
2131576 ac delco knock sensor 20$
accessories belt driveworks 935K6
upgraded AC belt to include tensioner - driveworks 378k4 + tensioner Dayco 89258 + fastenal m10x25 pn: 11115626
doug thorley thy-344y-c headers 860$
"fastenal "
qty 1 flanged head bolt m10x40 1.67$x1 pn: 11115629 a/c compressor to bracket
qty 3 flanged head bolt m8x30 0.94$x3 pn: 11115619 power steering pump to bracket
qty 3 flanged head bolt m10x70 2.76$x3 pn: 11115634 a/c compressor to bracket
qty 2 flanged head bolt m10x90 2.92$x2 pn: 11115637 alternator to bracket
qty 3 flanged head bolt m10x20 1.76$x3 pn: 11116067 torque convertor to flex plate
qty 50 x 2" inch long 1/16 heatshrink tubing 6$
qty 50 x 2" inch long 1/8 heatshrink tubing 6$
Wiring was done by 04colyZQ8 , price depends how much needs to be repaired and or modified starts around 300 and goes up my harness was cooked and cut in many places , he modified every and sent me instructions on what to do to the body harness.
tools list
cherry picker
transmission jack
soldering iron
socket set
socket wrench
pry bars
lots of extensions ranging from 3" - 24"
phillips + flathead screw drivers
-wrench time-
day 1 8am-7pm
parked the humvee on level ground , removed rear drive shaft , removed front drive shaft , exhaust down pipe bolts were seized at the manifold and at the flange to the exhaust, cut bolts at the exhaust flange side, drained transmission , drained transfer case ,removed transmission crossmember, unbolted transfer case from transmission - couldn't get it out exhaust pipe is in the way, removed pcm, removed airbox, removed power steering pump / reservoir , removed egr/evap components, removed exhaust manifold heat shield, unbolted exhaust manifold from head found 2 broken bolts with lots of exhaust leakage, removed battery , removed coolant over flow tank, removed fan shroud , removed radiator and condenser, disconnected fuel lines , disconnect transmission cooler lines from the transmission , disconnected more of the harness from driver side , removed alternator , disconnected a/C lines from the compressor and removed the lines, I'm probably missing something - there was a bunch on little odds and ends
Day 2 2pm-7pm cut the down pipe in half and removed both halves separately, finally was able to finagle out the transfer case , removed all the transmission bolts and pulled the transmission out the bottom , left the torque converter on the flex plate, hooked up the cherry picker and pulled the engine out of the top .
day 3 3pm-8pm
Cut off the 56 way plug going to the hummer body 1 wire at a time and soldered into the new 56 way plug provided from " 04colyZQ8 " he provided the wiring instructions and repaired / modified the v8 harness I sent him. Worked the harness slowly and methodically , Everything has been soldered and has two layers of heat shrink tubing.
Im kind of stuck for tomorrow , the engine load leveler had no good way of attaching to the i5 - i used a chain instead, and now i tried it on the v8 and there is no good way of attaching it to the v8 either , so ill be returning it and calling all the local performance shops to see if anyone has a lsx engine lift plate.
day 4 4pm-8pm
cutting, welding, grinding, painting, I built a custom cherry picker mount to assist in installing the engine. cleaned up some of the rust of the crossmember and the chassis.
day 5 11am-7pm
Mounted the cherry picker harness and realized I needed to get it closer to the engine to get clearance, so off to lowes to get some shackles . Started by removing the engine from the engine stand and replaced the rear cover gasket , then replaced the rear main seal , then cleaned up and painted the flex plate - then attached it, Dropped the engine in and realized I forgot to trim the body mounts, pulled the engine and trimmed the body mounts and then dropped the engine in again. I found I couldn't install the passenger engine mount bolt with the a/c compressor installed- so off it came , bolted the engine in , removed the cherry picker , tried to install the intake manifold , it ran into the fire wall so I grabbed a hammer and did some massaging of the pinch weld, and got the intake installed. I think if you have a 1 inch body lift the firewall massaging is probably not required.
day 6 9am-7pm
I feel like I didn't accomplish that much today, I started by calling around to some hydraulic shops and asked questions about what they can and cant make , so I mocked up the power steering lines and brought everything to a hydraulic shop , I then found how stiff the dot rated 3000 psi line is, so I picked up 3 of the -6 an to 3/8 compression , and brought it all back to the house and mocked it up again , I debated using -6 an hose or push loc hose , both were not rated high enough to take the pressure of power steering 1300-1600psi , so I went back to the shop and had them make some 2 -6 an lines that are dot 3000 psi lines. ( see attached fittings and lines they are still in mock up stages ) . I need to select a power steering cooler and route the return line with -6 an and 3/8 pushloc hose .
I taped off the doug thorley tri - y's headers to check fitment, driver side is gonna fit with no mods , passenger side is touching the floor pan and the outlet runs straight into the torsion bar - both can be easily remedied - im gonna use them... ( there still in mock up stages )
I finished out the night by running the needle scaler in preparation for rust repair, then used the air grinder with metal prep pads I got carried away and completely stripped the transmission cross member. ( its still in mock up prep stages )
day 7 4pm-11pm
filled new torque convertor and let it soak for a few hours , installed new torque convertor into transmission , painted chassis , painted transmission crossmember , installed transmission , installed cross member , had to loosen the motor mounts and push the whole engine to its most forward position possible on the current performance motor mounts. This will probably fix the passenger header from hitting the floor pan , but it still will run into the torsion bar and will need to be shortened about 2-3 inches and a 45 or 90 degree elbow installed.
Day 8 7pm-10:30pm
installed / removed the passenger manifold multiple times , cut , mocked up , and modified the passenger side doug thorley header , not super happy about how the welds turned out , but it will work.
Day 9 7pm-10pm
installed / removed the driver side manifold multiple time , cut , mocked up , and modified the driver side doug thorley header, welds turned out better , think i finally am getting the heat and wire speed dialed in for the metal.
Day 10 7pm-11:30pm
Almost a complete waste of time, I tried for about 3.5 hours of that time to mount the borg warner transfer case to the transmission, i finally threw in the flag and decided to mount the New Process 241 so in the last hour i was able to swap the bellhousing extension and install the NP241 - it went right in with ease, I then took a few pictures , it will not work without a SAS swap , the passenger torsion bar is in the way , the transmission and transfer case were still on the transmission jack and needed to raise 2-3 inches up, it also appears you will have to modify the transmission crossmember for front driveshaft clearance. (pictures on page 2) I'm not ready to put the Dana 44 up front , I wanna finish up the v8 swap, so ill pull the NP241 out and try again on the borg warner , I damaged the wires going into the electrical solenoid on the back of the borg warner case , im going to try to remove that before i try again, It would be nice if the current performance mounts had about another .5 to 1 inch so the motor could be shifted forward a little more.
http://s685.photobucket.com/user/darkmitsu/library/H3 swap pictures
Q. Will I need a gantry crane to pull and place the engine. A. no, I was able to pull and place the engine by it self with the hood on with a cherry picker.
Q. Will the I5 4l60 work on the v8 engine A. no, the bellhousing is different as well as the shaft going into the bellhousing
Q. what headers will work out of the box A. none that i can find , but with minimal mods the doug thorleys will fit
Q. what do you do about wiring A. there are many wiring companys I went with a forum member " 04colyZQ8 "
Q. what does a performance shop charge to do the swap A. I was quoted 30-60 hours at 100$ an hour
-parts list-
12573337 filler cap
12593348 filler cap o ring
12612350 oil pan gasket
rear main seal
rear cover gasket
cbm rear cover alignment tool 40$
hp tuners 499- 649$
-fuel lines ???
custom power steering lines 100-150$
-transmission dipstick tube ???
starter 65$
a/c compressor 61$
alternator 50$
H3 alpha 4l60e 40k miles 900$
LH8 120k miles 1600$
H3 alpha PCM + TCU 150$
flexplate with bolts 50$
current performance engine mounts 175$
exhaust manifold gasket
coil pack
transmission fluid
transfer case fluid
oil filter
oil
exhaust stud kit 30$
15-33806 ac delco a/c lines a/c compressor to condensor 110$
15-34365 ac delco a/c lines firewall to a/c compressor 80$
15-31055 ac delco a/c seals x 2 for the factory i5 lines 2x6$
25844416 ac delco heater hose kit 140$
23436 "gates" upper radiator hose 40$
23437 "gates" lower radiator hose 40$
dacco B85TMBX torque convertor 170$
89009 "dayco" idler pulley 20$
current performance motor mounts 163$
2131576 ac delco knock sensor 20$
accessories belt driveworks 935K6
upgraded AC belt to include tensioner - driveworks 378k4 + tensioner Dayco 89258 + fastenal m10x25 pn: 11115626
doug thorley thy-344y-c headers 860$
"fastenal "
qty 1 flanged head bolt m10x40 1.67$x1 pn: 11115629 a/c compressor to bracket
qty 3 flanged head bolt m8x30 0.94$x3 pn: 11115619 power steering pump to bracket
qty 3 flanged head bolt m10x70 2.76$x3 pn: 11115634 a/c compressor to bracket
qty 2 flanged head bolt m10x90 2.92$x2 pn: 11115637 alternator to bracket
qty 3 flanged head bolt m10x20 1.76$x3 pn: 11116067 torque convertor to flex plate
qty 50 x 2" inch long 1/16 heatshrink tubing 6$
qty 50 x 2" inch long 1/8 heatshrink tubing 6$
Wiring was done by 04colyZQ8 , price depends how much needs to be repaired and or modified starts around 300 and goes up my harness was cooked and cut in many places , he modified every and sent me instructions on what to do to the body harness.
tools list
cherry picker
transmission jack
soldering iron
socket set
socket wrench
pry bars
lots of extensions ranging from 3" - 24"
phillips + flathead screw drivers
-wrench time-
day 1 8am-7pm
parked the humvee on level ground , removed rear drive shaft , removed front drive shaft , exhaust down pipe bolts were seized at the manifold and at the flange to the exhaust, cut bolts at the exhaust flange side, drained transmission , drained transfer case ,removed transmission crossmember, unbolted transfer case from transmission - couldn't get it out exhaust pipe is in the way, removed pcm, removed airbox, removed power steering pump / reservoir , removed egr/evap components, removed exhaust manifold heat shield, unbolted exhaust manifold from head found 2 broken bolts with lots of exhaust leakage, removed battery , removed coolant over flow tank, removed fan shroud , removed radiator and condenser, disconnected fuel lines , disconnect transmission cooler lines from the transmission , disconnected more of the harness from driver side , removed alternator , disconnected a/C lines from the compressor and removed the lines, I'm probably missing something - there was a bunch on little odds and ends
Day 2 2pm-7pm cut the down pipe in half and removed both halves separately, finally was able to finagle out the transfer case , removed all the transmission bolts and pulled the transmission out the bottom , left the torque converter on the flex plate, hooked up the cherry picker and pulled the engine out of the top .
day 3 3pm-8pm
Cut off the 56 way plug going to the hummer body 1 wire at a time and soldered into the new 56 way plug provided from " 04colyZQ8 " he provided the wiring instructions and repaired / modified the v8 harness I sent him. Worked the harness slowly and methodically , Everything has been soldered and has two layers of heat shrink tubing.
Im kind of stuck for tomorrow , the engine load leveler had no good way of attaching to the i5 - i used a chain instead, and now i tried it on the v8 and there is no good way of attaching it to the v8 either , so ill be returning it and calling all the local performance shops to see if anyone has a lsx engine lift plate.
day 4 4pm-8pm
cutting, welding, grinding, painting, I built a custom cherry picker mount to assist in installing the engine. cleaned up some of the rust of the crossmember and the chassis.
day 5 11am-7pm
Mounted the cherry picker harness and realized I needed to get it closer to the engine to get clearance, so off to lowes to get some shackles . Started by removing the engine from the engine stand and replaced the rear cover gasket , then replaced the rear main seal , then cleaned up and painted the flex plate - then attached it, Dropped the engine in and realized I forgot to trim the body mounts, pulled the engine and trimmed the body mounts and then dropped the engine in again. I found I couldn't install the passenger engine mount bolt with the a/c compressor installed- so off it came , bolted the engine in , removed the cherry picker , tried to install the intake manifold , it ran into the fire wall so I grabbed a hammer and did some massaging of the pinch weld, and got the intake installed. I think if you have a 1 inch body lift the firewall massaging is probably not required.
day 6 9am-7pm
I feel like I didn't accomplish that much today, I started by calling around to some hydraulic shops and asked questions about what they can and cant make , so I mocked up the power steering lines and brought everything to a hydraulic shop , I then found how stiff the dot rated 3000 psi line is, so I picked up 3 of the -6 an to 3/8 compression , and brought it all back to the house and mocked it up again , I debated using -6 an hose or push loc hose , both were not rated high enough to take the pressure of power steering 1300-1600psi , so I went back to the shop and had them make some 2 -6 an lines that are dot 3000 psi lines. ( see attached fittings and lines they are still in mock up stages ) . I need to select a power steering cooler and route the return line with -6 an and 3/8 pushloc hose .
I taped off the doug thorley tri - y's headers to check fitment, driver side is gonna fit with no mods , passenger side is touching the floor pan and the outlet runs straight into the torsion bar - both can be easily remedied - im gonna use them... ( there still in mock up stages )
I finished out the night by running the needle scaler in preparation for rust repair, then used the air grinder with metal prep pads I got carried away and completely stripped the transmission cross member. ( its still in mock up prep stages )
day 7 4pm-11pm
filled new torque convertor and let it soak for a few hours , installed new torque convertor into transmission , painted chassis , painted transmission crossmember , installed transmission , installed cross member , had to loosen the motor mounts and push the whole engine to its most forward position possible on the current performance motor mounts. This will probably fix the passenger header from hitting the floor pan , but it still will run into the torsion bar and will need to be shortened about 2-3 inches and a 45 or 90 degree elbow installed.
Day 8 7pm-10:30pm
installed / removed the passenger manifold multiple times , cut , mocked up , and modified the passenger side doug thorley header , not super happy about how the welds turned out , but it will work.
Day 9 7pm-10pm
installed / removed the driver side manifold multiple time , cut , mocked up , and modified the driver side doug thorley header, welds turned out better , think i finally am getting the heat and wire speed dialed in for the metal.
Day 10 7pm-11:30pm
Almost a complete waste of time, I tried for about 3.5 hours of that time to mount the borg warner transfer case to the transmission, i finally threw in the flag and decided to mount the New Process 241 so in the last hour i was able to swap the bellhousing extension and install the NP241 - it went right in with ease, I then took a few pictures , it will not work without a SAS swap , the passenger torsion bar is in the way , the transmission and transfer case were still on the transmission jack and needed to raise 2-3 inches up, it also appears you will have to modify the transmission crossmember for front driveshaft clearance. (pictures on page 2) I'm not ready to put the Dana 44 up front , I wanna finish up the v8 swap, so ill pull the NP241 out and try again on the borg warner , I damaged the wires going into the electrical solenoid on the back of the borg warner case , im going to try to remove that before i try again, It would be nice if the current performance mounts had about another .5 to 1 inch so the motor could be shifted forward a little more.
http://s685.photobucket.com/user/darkmitsu/library/H3 swap pictures
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