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Old February 21st, 2010, 06:03 PM   #1
kkodet
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Default World Expedition Suburban Build - Cummins/NV4500/Dana 60 - Build back on?

Here is what I am starting with: I picked up this 1999 Suburban 3/4 in Detroit off Craigslist for $1,600. It is fully loaded, it even has heated seats. The previous owner started dismantling the 454 because he thought it was bad. The truck has just over 100,000 on the ticker, is rust free, and appears to have been garage kept.



Here is the build plan:

1990 Cummins 12 valve motor
1998 Dodge Ram NV4500 and 241 transfer case
Swap in a Ford Dana 60 front axle
3.50 gears
H1 Beadlocks
ARB Front bumper/warn winch
Detroit Lockers Front/Rear

Here is a pic of the donor engine. I bought the entire 2wd truck that had been rolled for $1,200. It runs great and has 200,000 miles on it:



Bought this piece of crap for $350.00 from a local scrapper. Had a HP dana 60 front and a Chevy 35 spline Dana 60 rear. Much to my surprise, both axles ended up having Detroit lockers in them.




Lastly, I called Ryan at B&L auto wrecking out in Oregon. He has always gotten me great prices on late model stuff. He sold me this 1998 Ram NV4500 with everything else (flywheel, bellhousing, clutch, pedal assembly, slave, etc.) for $1,450 shipped to my door. This all came out of a Truck with 80,000 miles that had gotten wrecked.

I traded a friend of mine a junk low pinion 77 Ford Dana 60 for a 241 Diesel T-case (large 29 spline is specific to diesel sticks)



Now that I have all the parts, let the building began!

My end goal is to have a wheelable tow rig that I can also take anywhere with the whole family and tons of gear.

Last edited by kkodet; December 24th, 2011 at 11:19 AM.
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Old February 21st, 2010, 06:07 PM   #2
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nice build love it
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Old February 21st, 2010, 06:16 PM   #3
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exactly the kind of build i need for my soon to be 4kids!
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Old February 21st, 2010, 06:16 PM   #4
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Looks like a fun build. Good luck.
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Old February 21st, 2010, 06:27 PM   #5
93XJcountry
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looks like its gonna be sweet
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Old February 22nd, 2010, 04:45 PM   #6
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hell yeah. now get to work. the EXACT plans I have for my 96 suburban. so whats up with the 454 that was in it? maybe i will go that route instead of the cummins swap.
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Old February 22nd, 2010, 04:52 PM   #7
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Quote:
Originally Posted by chevotass View Post
hell yeah. now get to work. the EXACT plans I have for my 96 suburban. so whats up with the 454 that was in it? maybe i will go that route instead of the cummins swap.
I may sell it, or I may shelf it for my 56 chevy. I haven't decided yet.
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Old February 22nd, 2010, 08:24 PM   #8
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both had detroits in em? You luck SOB!
:)
totally badass btw
I am trying to convince my wife to let me put a 4bt in her 99 burban. Better mileage for taking the kids everywhere.
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Old February 22nd, 2010, 08:30 PM   #9
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Sounds awesome. Its hard to believe that in 1999 someone paid about 40k bucks for that suburban
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Old February 23rd, 2010, 12:25 PM   #10
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Looks like a sweet build.... keep us updated!!!
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Old February 23rd, 2010, 12:37 PM   #11
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Oh man, I'm excited about this! GET TO WORK!!
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Old February 23rd, 2010, 12:49 PM   #12
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Awesome idea!
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Old February 23rd, 2010, 04:48 PM   #13
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Well, I dismantled the front axle and started cleaning/sandblasting everything. I now officially have sand in places I never want sand again.

This is my state of the art high tech sandblast booth



The front axle completely blasted. I should have left the lower kingpin bearing races in and pulled them afterwards. I wouldn't have had to be so careful blasting around the machined surfaces.



Blasting everything is nice, because you find things you don't want to. This is the passenger side knuckle.



After much thinking about it, I figure this crack could be twenty years old and shows no sign of separation. So I heated the knuckle up with the torch and welded it. I know this weld is really ugly, but keep in mind I was welding already molten material. I think it will be fine, but I will keep an eye on it.



I've got about one more solid day of sand blasting and I should have all the front end parts cleaned up and painted and ready for re-assembly.
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Old February 23rd, 2010, 04:53 PM   #14
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Subscribed. Sounds like it will be a cool build.
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Old February 23rd, 2010, 07:11 PM   #15
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thats one nice looking suburban, good deal, cant wait to see more
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Old February 23rd, 2010, 07:16 PM   #16
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I'd recommend plating that knuckle. Ferd d60 knuckles aren't the strongest, and that's a common cracking/breaking point. If someone had bothered to put detroits f&r and had upgraded the rear to a gm d60 35-spline axle, I'm guessing they didn't live a charmed life. Might even be a good idea to throw an alignment bar in there to verify it is straight.
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Old February 24th, 2010, 09:11 AM   #17
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Quote:
Originally Posted by JohnnyJ View Post
I'd recommend plating that knuckle. Ferd d60 knuckles aren't the strongest, and that's a common cracking/breaking point. If someone had bothered to put detroits f&r and had upgraded the rear to a gm d60 35-spline axle, I'm guessing they didn't live a charmed life. Might even be a good idea to throw an alignment bar in there to verify it is straight.
These axles were definitely beat the hell out of. However, how will plating make the knuckle stronger? Wouldn't it just make it prettier? I don't have an alignment bar, so I'll just hope for the best. The truck did run/drive down the road.
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Old February 24th, 2010, 09:44 AM   #18
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Does adding a guesset to a cage only make it prettier? Does fishplating a frame only make it prettier?

In the ford 60 knuckle, there's space to make it thicker in the areas they are known for cracking. Plating them beefs them up at less cost than buying an aftermarket replacement knuckle.

http://www.pirate4x4.com/forum/showt...plating&page=8
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Old February 24th, 2010, 09:50 AM   #19
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Quote:
Originally Posted by JohnnyJ View Post
Does adding a guesset to a cage only make it prettier? Does fishplating a frame only make it prettier?

In the ford 60 knuckle, there's space to make it thicker in the areas they are known for cracking. Plating them beefs them up at less cost than buying an aftermarket replacement knuckle.

http://www.pirate4x4.com/forum/showt...plating&page=8
AH, you mean gusseting . When you said plating, I thought you meant some sort of Powder coating or Chroming. I was trying to be nice, but honestly thought you were smoking some wacky tobacky.

Gusseting sounds like a good idea to me. Thanks for the idea!

Last edited by kkodet; February 24th, 2010 at 10:06 AM.
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Old February 24th, 2010, 11:18 AM   #20
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Quote:
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....I don't have an alignment bar....
Get one, I used a chunk of 1.1875" TG&P 1045 shafting, and had some "pucks" made up to match the carrier bearing races, I've checked (5) front 60's that were either in or recently pulled from running stock-ish trucks to check them and none were straight, even the one I ended up buying was 0.188 out on the long side, most were 0.375-0.500 out, one I couldn't even pass the bar thru.
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