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Old 12-13-2011, 09:57 PM
rockrod rockrod is offline
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Default 1994 FZJ80 5.3l and 4L60e swap

So add me to the list of the vortec swappers.I have owned my 80 for a little over a year now and while it's been a great truck, the lack of power is getting old.



I was given the green light by the CFO to move forward with the swap.I sourced a low mileage 2006 Vortec L33 5.3l engine and 2003 4L60e 4 spd automatic transmission.



The L33 is an all aluminum V8 and is based on the LS6. It runs Z06 heads, 9.9 compression ratio, and the cam has a bit more lift (same duration) over an iron block 5.3l motor. It's rated at 310 hp and 335 ft/lbs of torque. It will make a good bit more than that because I had the PCM tuned for performance. It will be closer to 350hp and 350 ft/lbs of torque.The last few weeks have been mostly a mission of gathering the parts. I relied heavily on the previous LSx swap threads to come up with the list and I have manage to gather a lot of what's needed. I am still waiting on the t-case adapter from Advanced. I am keeping the stock full time t-case.A few more pics of the motor with the f-body pan swap done and LS3 exhaust manifolds installed:





I am doing my own wiring harness adaptation and have built my own fuse block to run the motor:



I am using an FJ80 shifter to keep the stock look:



I am using a dual fan 2 speed unit from a mid '90s lincoln continental. It's essentially two taurus fans that run together. The PCM will control the fans.



I started the dissasembly of the 80 last night. This project will move pretty slow since I work full time and my wife and I are raising 2 year old triplets. I don't have a lot of free time so work will mostly happen at night.

Stay tuned!
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1994 FZJ80. Elocked, MAF 3/2 Lift, BFG 315 KM2s, stock 4.10s, ARB bullbar and a Warn 8074 winch.

powered by an all-aluminum 335hp L33 Vortec V8

2004 Kona Stinky dee-lux.
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Old 12-13-2011, 09:58 PM
rockrod rockrod is offline
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pile of parts is getting bigger:



front end getting stripped down:





2WD 4L60e I will be using:



Notice the difference in the MLPS on the side of the transmission. 2004 was the transition year and GM switched from the 2 plug style to the single plug style for the later years. My engine is a 2006 and the trans is a 2003, so a swap to the later style to update this trans is in order. It's an R&R deal:



more tomorrow night.
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1994 FZJ80. Elocked, MAF 3/2 Lift, BFG 315 KM2s, stock 4.10s, ARB bullbar and a Warn 8074 winch.

powered by an all-aluminum 335hp L33 Vortec V8

2004 Kona Stinky dee-lux.
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Old 12-13-2011, 10:13 PM
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Keep up the good work! Will definitely be following!
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1997 Honda civic DX( all stock DD)
1972 Toyota FJ40(4" lift, FJ60 axles, FJ60 4speed with split case, 35's, Detroit locker rear, Lockright front, Marlin Highsteer, 105"WB, Saginaw with GM tilt column, soon to have: 30spline longfields, inners/outters, toybox.
1967 Porsche 912(100% stock)


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Old 12-13-2011, 10:57 PM
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Sounds like fun! Let me know if you have any questions... I have about 90,000 miles on my 5.3 vortec swap in my 60 and I have learned a lot of things along the way..
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Old 12-13-2011, 11:09 PM
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PM Sent on the old motor. I'll be watching too.
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1993 FZJ80 "enhanced", re-built Engine, and prototype GOBI Stealth roof rack
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Old 12-13-2011, 11:35 PM
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Btw, I'd recommend going with a mechanical fan if you can.. I just looked through this again and thought that. My electric defile cooled well but were never really that reliable.
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Old 12-14-2011, 06:16 AM
rockrod rockrod is offline
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Quote:
Originally Posted by rover67 View Post
Btw, I'd recommend going with a mechanical fan if you can.. I just looked through this again and thought that. My electric defile cooled well but were never really that reliable.
The fan I am using is an OEM ford fan. here's a shot of it sitting on the stock '94 radiator.



If it doesn't work, then I will switch to the mechanical fan.
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1994 FZJ80. Elocked, MAF 3/2 Lift, BFG 315 KM2s, stock 4.10s, ARB bullbar and a Warn 8074 winch.

powered by an all-aluminum 335hp L33 Vortec V8

2004 Kona Stinky dee-lux.
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Old 12-14-2011, 11:19 AM
Overlander Overlander is offline
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Nice work -

Question - what do you planning on doing with the Power Steering?! Are you going to adapt the Toyota P/S pump to the new engine, or are you going to use the GM P/S pump and just swap the lines to and from it?! If so, who's going to make custom hoses for ya?

Good luck with the swap - looking good.

James
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'95 FZJ80 with Lockers; Home made sliders - and it shows... 285 DuraTracs; Seat covers, CB radio
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Old 12-14-2011, 01:58 PM
rockrod rockrod is offline
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Quote:
Originally Posted by Overlander View Post
Nice work -

Question - what do you planning on doing with the Power Steering?! Are you going to adapt the Toyota P/S pump to the new engine, or are you going to use the GM P/S pump and just swap the lines to and from it?! If so, who's going to make custom hoses for ya?

Good luck with the swap - looking good.

James
good question. The solution is very easy. The toyoto steering box uses a 5/8s ORB fitting. Russell Performance makes the powerflex line of teflon braid hoses designed just for hydraulics and high pressure applications. They sell adapters that fit the gm/saginaw pump and the steering box that allow -06 JIC style fitting equipped hose to join the two up. I used a very similar setup on my old jeep CJ-7 crawler and it's full hydro steering. The hose is built using regular hand tools.

here's more info on the hose construction:

http://www.russellperformance.com/mc...steering.shtml

and these are the fittings for the pump and steering box

http://www.russellperformance.com/mc...t/fit_ps.shtml
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1994 FZJ80. Elocked, MAF 3/2 Lift, BFG 315 KM2s, stock 4.10s, ARB bullbar and a Warn 8074 winch.

powered by an all-aluminum 335hp L33 Vortec V8

2004 Kona Stinky dee-lux.
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Old 12-14-2011, 02:01 PM
rockrod rockrod is offline
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Also forgot to mention - integrating the toyota AC system. This will be a bit more challenging but I think I found a solution for this as well. I have to have a custom discharge and suction hose made up so that they will fit the toyota condensor and evap ports on one side and the denso compressor on the engine side.
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1994 FZJ80. Elocked, MAF 3/2 Lift, BFG 315 KM2s, stock 4.10s, ARB bullbar and a Warn 8074 winch.

powered by an all-aluminum 335hp L33 Vortec V8

2004 Kona Stinky dee-lux.
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