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Discussion Starter · #4 ·
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Very cool project. I’ll have lots of questions throughout your build I’m sure.

First: What transfer case are you using?
I am still contemplating which direction I am going to go on the transmission.
1. Use the 6l80e and factory transfer case although it is drivers side drop. Run in 2wd for now. I have a drivers side drop dana 44 for a SOA upgrade slated for this fall.
2. Use the 6l80e and source a NP241 passenger drop manual transfer case.
3. Use the existing 4l60e and transfer case, install a 2500 stall converter and transmission cooler, see how long she last.
 

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I am still contemplating which direction I am going to go on the transmission.
1. Use the 6l80e and factory transfer case although it is drivers side drop. Run in 2wd for now. I have a drivers side drop dana 44 for a SOA upgrade slated for this fall.
2. Use the 6l80e and source a NP241 passenger drop manual transfer case.
3. Use the existing 4l60e and transfer case, install a 2500 stall converter and transmission cooler, see how long she last.
I'd go with #2 and find a FZJ80 front axle to build the front suspension around. Of course you could go with #2 and pick up a passenger drop Dana 44 out of a FSJ truck.

At least you have options.
 

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Discussion Starter · #6 ·
I'd go with #2 and find a FZJ80 front axle to build the front suspension around. Of course you could go with #2 and pick up a passenger drop Dana 44 out of a FSJ truck.

At least you have options.
I am leaning towards #2 option as well, would be nice to rid of the GM 4x4 electronics. I jumped the gun a little early last year and bought a set of 8 lug 3/4 ton leaf spring axles out of an older Chevy truck, Dana 44 front, eaton posi rear axle, both with 4.10 gears. Probably should have waited a bit. Now I am trying to figure out whether to incorporate into the project or sell and go a different direction. I am trying to not get ahead of myself, however I have had the diesel sitting in the crate for almost a year and just want to get it in and hear it run, lol.
 

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I am leaning towards #2 option as well, would be nice to rid of the GM 4x4 electronics. I jumped the gun a little early last year and bought a set of 8 lug 3/4 ton leaf spring axles out of an older Chevy truck, Dana 44 front, eaton posi rear axle, both with 4.10 gears. Probably should have waited a bit. Now I am trying to figure out whether to incorporate into the project or sell and go a different direction. I am trying to not get ahead of myself, however I have had the diesel sitting in the crate for almost a year and just want to get it in and hear it run, lol.
I hear ya. I ditched all that electronic junk and couldn't be happier. Don't worry about jumping the gun. I've had two passenger drop leaf spring Dana 44s sitting in my barn for over a year waiting for my lazy butt to do a SAS. Time is tough to find and my heap works really well in its current configuration so it's hard to change.

Your project definitely deserves patience and planning. If properly executed it could be one of the best 4x4 projects of 2020 here on 355nation.

Keep the build updates coming.
 

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Discussion Starter · #8 ·
I hear ya. I ditched all that electronic junk and couldn't be happier. Don't worry about jumping the gun. I've had two passenger drop leaf spring Dana 44s sitting in my barn for over a year waiting for my lazy butt to do a SAS. Time is tough to find and my heap works really well in its current configuration so it's hard to change.

Your project definitely deserves patience and planning. If properly executed it could be one of the best 4x4 projects of 2020 here on 355nation.

Keep the build updates coming.
How are you shifting the transfer case? I will be replacing the center console with a metal one (police SUV style) for public safety equipment so I wont have the floor space available for a manual shifter.
 

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How are you shifting the transfer case? I will be replacing the center console with a metal one (police SUV style) for public safety equipment so I wont have the floor space available for a manual shifter.
I called up Jon at JB Fab and he built me a custom shifter setup for my Dana 20. I cannot recommend him any higher. Great guy with excellent customer service.


I considered using a police console (I'm a cop and have access to lots of parts if I "borrow" them). I decided not to go that route because I wanted more of a factory look to the cab.

I cut out the factory center console and mounted the shifters. I think it turned out decent but a better fab guy could have done a better job I'm sure.

Vehicle Car Auto part Subcompact car Hatchback
 

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Discussion Starter · #10 ·
I called up Jon at JB Fab and he built me a custom shifter setup for my Dana 20. I cannot recommend him any higher. Great guy with excellent customer service.


I considered using a police console (I'm a cop and have access to lots of parts if I "borrow" them). I decided not to go that route because I wanted more of a factory look to the cab.

I cut out the factory center console and mounted the shifters. I think it turned out decent but a better fab guy could have done a better job I'm sure.

View attachment 340222
I called up Jon at JB Fab and he built me a custom shifter setup for my Dana 20. I cannot recommend him any higher. Great guy with excellent customer service.


I considered using a police console (I'm a cop and have access to lots of parts if I "borrow" them). I decided not to go that route because I wanted more of a factory look to the cab.

I cut out the factory center console and mounted the shifters. I think it turned out decent but a better fab guy could have done a better job I'm sure.

View attachment 340222
I called up Jon at JB Fab and he built me a custom shifter setup for my Dana 20. I cannot recommend him any higher. Great guy with excellent customer service.


I considered using a police console (I'm a cop and have access to lots of parts if I "borrow" them). I decided not to go that route because I wanted more of a factory look to the cab.

I cut out the factory center console and mounted the shifters. I think it turned out decent but a better fab guy could have done a better job I'm sure.

View attachment 340222
Now that I see your setup, I think I could do something like that. I need to measure my new console, it is out of a Trailblazer and I believe starts from the factory cupholder back.

BTW...nice to meet a fellow LEO on the 355 board here. ;-)
 

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Settled on the Dana 300 for the transfer case. I am waiting on the adapter to come in to mate it to the 6l80e
I’d love to see a Dana 300 HD output shaft housing and a set of Lomax Gears combined with your drivetrain.

Your truck stands to be pretty unique already. Keep the updates coming!
 
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