LS Swap To-Do List

The priority of things:

1. Holden Commodore VZ Series II SS-V Thunder ute delivered (received 08.08.2015).
2. Engine (L76) and gearbox (4L65E) removed from ute (completed 16.08.2015).
3. Source the engine mount adapter plates (received 04.09.2015).
4. Drop harness + ECU to harness mod guy + discuss requirements (delivered 01.09.2015).
5. Source steel for the test stand (picked-up 03.09.2015).
6. Finish drawing the engine + gearbox test stand in CAD (completed 04.09.2015).
7. Remove VZ fuel tank, fuel lines, etc... gut the ute (completed 06.09.2015).
8. Source exhaust headers (picked-up 07.09.2015).
9. Source the LS3 dipstick + dipstick tube + dipstick tube O-ring (received 15.09.2015).
10. Source a Fel Pro oil pan gasket (received 16.09.2015).
11. Source a radiator + electric cooling fans (picked-up Thu 01.10.2015).
12. Pick-up modified harness + unlocked computer (picked-up Thu 01.10.2015).
13. Source castor wheels for the test stand (received 06.10.2015).
14. Weld-up the test rig and fit castors (final piece picked-up on Mon 19.10.2015).
15. Get rid of the VZ shell on eBay (picked-up on 22.10.2015).
16. Fit engine + gearbox on test stand (complete Fri 23.10.2015).
17. Source radiator hoses to-suit (picked-up Wed 28.10.2015).
18. Source a VE V8 MAF sensor (picked-up Thu 29.10.2015).
19. Bypass ATF cooler (completed Thu 29.10.2015).
20. Plumb the radiator + radiator hoses onto the engine/test stand (completed Thu 29.10.2015).
21. Bypass the steering rack (power steering circuit) (completed Fri 30.10.2015).
22. Plumb the coolant reservoir onto the engine/test stand (completed Fri 30.10.2015).
23. Source 2 x pre-cat oxygen sensors (picked-up Fri 30.10.2015).
24. Fit headers + O2 sensors onto the engine (completed Fri 30.10.2015).
25. Plumb VZ fuel tank + lines + filter onto the engine/test stand (completed Fri 30.10.2015).
26. Source a battery/starter pack (borrowed JtC's Fri 30.10.2015).
27. Plug-in the modified harness to all engine + gearbox sensors (completed Fri 30.10.2015).
28. Thread repair on right bank exhaust manifold bolt hole (completed Mon 02.11.2015).
29. Wire up the fuel pump + starter + fans + ignition + battery (completed Sun 08.11.2015).
30. Source a Wi-Fi OBD2 adaptor for diagnostics (completed Sun 08.11.2015).
31. Source OBD2 scanning software for the laptop/iPhone (completed Sun 08.11.2015).
32. Source fluids + filters and fill all reservoirs (completed Sun 08.11.2015).
33. TEST RUN #1: check the ECU and harness works (completed Sun 08.11.2015).
34. Finalise the OBD2 adaptor and software.
35. Source new front and rear crankshaft seals (ordered 18.11.2015, received 20.11.2015).
36. Source an EFI fuel tank to suit the Impala (ordered 12.11.2015, received 24.11.2015).
37. Source a transmission shift adapter (ordered 12.11.2015, received 24.11.2015).
38. Pull the L76 off the 4L65E (completed Sat 05.11.2015).
39. Fit a new rear crankshaft seal (rear main seal) onto the L76 (completed Sat 05.11.2015).
40. Fit the Holley oil pan onto the L76 (completed Sat 05.11.2015).
41. Fit the LS3 dipstick onto the L76 (completed Sat 05.11.2015).
42. Remove air con compressor (completed Sat 05.11.2015).
43. Remove alternator (completed Sat 05.11.2015).
44. Remove power steering pump + water pump + sensors (completed Sun 20.12.2015).
45. Degrease and clean the L76 (completed Sun 20.12.2015).
46. Paint the L76 Chevrolet orange (completed Sun 20.12.2015).
47. Fit engine mount adaptor plates (completed Sun 20.12.2015).
48. Degrease and clean the 4L65E (completed Tue 22.12.2015).
49. Paint the 4L65E with clear coat (completed Tue 22.12.2015).
50. Reattach the 4L65E to the L76 (completed Tue 22.12.2015).
51. Paint inlet manifold + coils satin black (completed Thu 31.12.2015).
52. Measure existing tail-shaft length (completed Thu 31.12.2015).
53. Remove the 327 + Powerglide from the Chev (completed Sat 16.01.2016).
54. Strip + clean engine bay (completed 06.02.2016).
55. Paint engine bay with etch primer (complete 07.02.2016).
56. Paint engine bay with satin black enamel - first coat (complete 10.02.2016).
57. Paint engine bay with satin black enamel - final coat (complete 13.02.2016).
58. Paint engine bay with clear coat (complete 17.02.2016).
59. Clean and fit the alternator, PS pump and tensioner to the LS (complete 21.02.2016).
60. Source new oil pressure light sender/switch (complete 24.02.2016).
61. Source transmission breather T-piece (received 25.02.2016).
62. Re-coat engine bay with satin black (complete 26.02.2016).
63. Fit auto transmission cooling pipes (complete 27.02.2016).
64. Source oil sender T-piece adapter (purchased 24.02.2016, received 07.03.2016).
65. L76 + 4L65E into the Chev. Test-fit #1: (complete 29.03.2016)
66. verify if the engine mount adapters locate the engine correctly (10 mm packers required).
67. verify a new ancillary drive is required (alternator fouls X-member).
68. verify the transmission fits (close, hammer-out tunnel near servo).
69. verify the location of the gearbox cross member (looks close at first sighting).
70. verify if the headers fit (close, move engine rearward).
71. verify the driver-side coil packs clear the master cylinder (clear!).
72. Remove the L76 + 4L65E from the Chev (complete 29.03.2016).
73. Hammer-out transmission tunnel to clear the servo (complete 30.03.2016).
74. Source a new ancillary drive for the L76 to suit the Impala (received 04.04.2016).
75. Move engine mounts rearward by 33 mm (complete 21.04.2016).
76. Manufacture new (taller) engine mount pedestals (complete 23.04.2016).
77. Paint the new pedestals + ancillary drive brackets satin black (complete 24.04.2016).
78. L76 + 4L65E into the Chev. Fitting #2 (complete 30.04.2016):
79. Verify if the engine mounts + new pedestals locate the engine correctly (done!).
80. Verify the transmission fits (done!).
81. Verify if the headers fit (done!).
82. Verify the location of the gearbox cross member (complete 15.05.2016).
83. Cut-off the existing transmission cross member chassis rail saddles (complete 21.05.2016).
84. Source a new PS pump inlet pipe to clear the ancillary drive bracket (received 25.05.2016).
85. Fit the new PS pump inlet pipe (complete 25.05.2016).
86. Manufacture new transmission cross member chassis rail saddles (complete 25.05.2016).
87. Modify the ancillary drive bracket  to clear the new PS pump inlet pipe (complete 26.05.2016).
88. Bolt the power steering pump into place (complete 26.05.2016).
89. Fit the rest of the new ancillary drive to the L76 (complete 29.05.2016).
90. Source a new PS pump inlet pipe to clear the ancillary drive belt (picked-up 08.06.2016).
91. Weld the new transmission cross member chassis rail saddles into place (complete 11.06.2016).
92. Modify the transmission cross member (complete 25.06.2016).
93. Bolt the transmission cross member in and mount the transmission (complete 18.07.2016).
94. Mock-up the park brake arrangement (complete 18.07.2016).
95. Source 5/16" UNC threaded rod + 5/16" UNC coupling nut + cable (completed 23.07.2016).
96. Assemble park brake (completed 30.07.2016).
97. Fit transmission linkage (complete 30.07.2016).
98. Remove original fuel tank (complete 13.08.2016).
99. Cut hole in boot/trunk floor for access to the in-tank fuel pump/sender (complete 14.08.2016).
100. Dummy-up new fuel tank (complete 14.08.2016).
101. Source a new (longer) ancillary drive belt. Ordered 2055 mm long (received 18.08.2016).
102. Source new fuel tank hanger bolts (received 18.08.2016).
103. Source fuel hose (received 19.08.2016).
104. Source Corvette filter/regulator + plumbing hardware (received 25.08.2016).
105. Fit EFI pump and sender to the tank (complete 27.08.2016).
106. Source exhaust manifold gaskets (received 30.08.2016).
107. Source a new ancillary drive belt. Ordered 2020 mm long (received 30.08.2016).
108. Fit EFI fuel tank (complete 03.09.2016).
109. Fit Corvette EFI fuel filter (complete 03.09.2016).
110. Verify the location/length of all power steering lines (complete 12.09.2106).
111. Plumb the supply/return fuel hoses between the pump and filter (complete 06.09.2016).
112. Source AN fittings and hard line for the fuel system (picked-up 15.09.2016).
113. Source AN fittings and hose for the power steering system (picked-up 15.09.2016).
114. Plumb the fuel hard lines from the filter to the engine (complete 18.09.2016).
115. Plumb the fuel tank vent (complete 27.09.2016).
116. Plumb the power steering system (complete 27.09.2016).
117. Grit blast the headers (complete 28.09.2016).
118. Verify the location of the radiator (complete 02.10.2016). Omit spacer.
119. Dummy-up headers, verify if cats will be used (complete 02.10.2016). Yes, use cats!
120. Cut engine pipes and tie the exhaust to the trans cross-member (complete 02.10.2016).
121. Paint headers (complete 03.10.2016).
122. Modify the radiator to bolt directly to the radiator support w/o spacer (complete 08.10.2016).
123. Have the radiator modified for Commodore hoses (picked-up 12.10.2016).
124. Source AN fittings for the ATF cooling system (picked-up 15.10.2016).
125. Fabricate thermo fan shroud (complete 15.10.2016).
126. Fabricate thermo fan mounts (complete 15.10.2016).
127. Mount the radiator (complete 16.10.2016).
128. Fit electric thermo fan (complete 16.10.2016).
129. Fabricate bottom coolant transfer pipe mounting brackets (complete 16.10.2016).
130. Plumb the cooling system bottom hose assembly (complete 16.10.2016).
131. Plumb the ATF cooling lines (complete 16.10.2016).
132. Source a top radiator hose that suits (picked-up 21.10.2016).
133. Plumb the cooling system top hose + trim fan shroud to suit (complete 22.10.2016).
134. Measure required tailshaft length at full-droop & full compression (complete 22.10.2016).
135. Verify the final length of the tailshaft (complete 22.10.2016) 1,545mm (existing less 80 mm).
136. Fit fuel tank filler neck (complete 22.10.2016).
137. Mount the oil pressure sensor + adaptor + oil sender (complete 22.10.2016).
138. Wire the oil pressure sender using the existing Chev wire (complete 22.10.2016).
139. Ensure all sensors are bolted down before the headers go on (complete 22.10.2016).
140. Source new exhaust header bolts (received 24.10.2016).
141. Source steam pipe 10 mm to 6 mm hose reducer (received 27.10.2016).
142. Source a new (shorter) tailshaft + new universal joints (picked-up 28.10.2016).
143. Fit the new tailshaft (complete 30.10.2016).
144. Fit new sparkplugs and leads (complete 30.10.2016).
145. Fit headers (complete 30.10.2016).
146. Fit the engine oil dipstick tube (complete 30.10.2016).
147. Connect the gearbox wiring harness (complete 30.10.2016).
148. Connect the engine-half of the wiring harness (complete 30.10.2016).
149. Connect the heater hoses (complete 30.10.2016).
150. Source intake bend + pipe + clamps + pod filter (picked-up 31.10.2016).
151. Source top radiator hose clamps for 44 mm OD (picked-up 05.11.2016).
152. Source fuel tank filler neck hose clamps for 62 mm OD (picked-up 05.11.2016).
153. Fit top radiator hose clamps (complete 06.11.2016).
154. Fit fuel tank filler neck hose clamps (complete 06.11.2016).
155. Trim the radiator shroud to suit intake (complete 07.11.2016). No good! Need different fan.
156. Open-up the clutch master hole in the firewall to ~ 3" dia (complete 07.11.2016).
157. Line hole with split rubber hose (complete 07.11.2016).
158. Feed the wiring loom through the firewall using the clutch master hole (complete 07.11.2016).
159. Mount the transmission ECU (complete 07.11.2016).
160. Source new exhaust flange gaskets (received 10.11.2016).
161. Source Engine ECU + Trans ECU M6 anti-vibration mounts (received 14.11.2016).
162. Source different profile radiator fan - Ford Falcon FG (picked-up 17.11.2016).
163. Test thermo fan -> runs high speed only, low speed resistor burnt out (complete 17.11.2016).
164. Source Dexron VI ATF (picked-up 18.11.2016).
165. Source DEX-COOL Extended Life coolant (picked-up 18.11.2016).
166. Source steam pipe 10 mm hose (picked-up 20.11.2016).
167. Source steam pipe 6 mm hose (picked-up 20.11.2016).
168. Fit thermo fan (complete 20.11.2016).
169. Wire the fuel sender ground (complete 20.11.2016).
170. Wire the fuel pump ground (complete 20.11.2016).
171. Mount the intake pipe + MAF + pod filter (complete 20.11.2016).
172. Plumb the cooling system steam pipe (complete 20.11.2016).
173. Clean-up battery tray + paint (complete 20.11.2016).
174. Fit battery tray + battery (complete 22.11.2016).
175. Delete the existing Chev alternator wire (complete 22.11.2016).
176. Hole through firewall for battery positive/thermo fan/starter wires (complete 22.11.2016).
177. Source the starter trigger relay/base. Reuse existing VZ relay. (complete 24.11.2016).
178. Source a plug for the thermo fan (complete 24.11.2016).
179. Source a longer silicon reducer section (swap shorter section) (complete 24.11.2016).
180. Source new battery cable/lugs/terminals (complete 25.11.2016).
181. Create new battery/ground cables (complete 26.11.2016).
182. Wire the battery positive/starter/alternator/ground harness (complete 26.11.2016).
183. Wire the existing Chev battery positive harness (to horn relay) (complete 26.11.2016).
184. Wire constant power source (red 2 x 6mm wires) (complete 26.11.2016).
185. Wire the fuel pump (purple 4mm wire). Run wire under carpet PS (complete 26.11.2016).
186. Wire the starter relay. Wire from Chev starter trigger + grey 2mm wire (complete 26.11.2016).
187. Wire the thermo fan (green 2 x 5mm wires) (complete 26.11.2016).
188. Temporarily hang the cats from the chassis (complete 26.11.2016).
189. Wire the thermo fan ground (complete 27.11.2016).
190. Wire ignition on (pink 4mm wire) (complete 27.11.2016).
191. Wire into the brake circuit (red 2mm wire) (complete 27.11.2016).
192. Wire the reverse lights (yellow 2mm wire) (complete 27.11.2016).
193. Wire accelerator pedal (plug-in harness) (complete 27.11.2016).
194. Add all fluids (complete 27.11.2016).
195. Test run the engine (complete 27.11.2016).
196. Test drive #1 (complete 27.11.2016).
197. Source speedo control unit (received 29.11.2016).
198. Swap buzzing fuel pump relay with neighbouring relay (complete 02.12.2016).
199. Grit blast bonnet latch (complete 02.12.2016).
200. Grit blast bonnet hinges (complete 02.12.2016).
201. Paint bonnet latch (complete 03.12.2016).
202. Paint bonnet hinges (complete 03.12.2016).
203. Fit the bonnet latch (complete 04.12.2016).
204. Fit the bonnet hinges (complete 04.12.2016).
205. Fit bonnet (complete 04.12.2016).
206. Mount the accelerator pedal (complete 04.12.2016).
207. Test Drive #2 (complete 04.12.2016).
208. Add body to engine earth strap (complete 06.12.2016).
209. Remove existing headlight high beam dip switch (complete 06.12.2016).
210. Source a headlight high beam dip switch (picked-up Wed 07.12.2016).
211. Fit new headlight high beam dip switch (complete Wed 07.12.2016).
212. New exhaust (complete Fri 09.12.2016).
213. Mount the relay block (complete Sun 11.12.2016).
214. Mount the fuse block (complete Sun 11.12.2016).
215. New tyres (x 4) and wheel alignment (Mon 12.12.2016).
216. Fix buzzing fuel pump relay (complete Thu 15.12.2016).
217. Mount the engine ECU (complete Sun 15.01.2017). Temporary.
218. Mount the OBD2 interface plug (complete Sun 15.01.2017).
219. Mount the speedo control unit + connect speedo cable (complete Sat 18.02.2017).
220. Wire the speedo control unit ground (complete Sat 25.02.2017).
221. Wire the speedo control unit VSS feed (purple 2mm wire) (complete Sun 26.02.2017).
222. Wire the speedo control unit calibration switch (complete Sun 26.02.2017).
223. Calibrate the speedometer (complete Fri 31.03.2017).
224. Engineer check and to-do list (pick-up Sat 15.04.2017).
225. Swap rear indicators to flash the reverse lights (complete Sat 06.05.2017).
226. Seal boot floor with velcro-attached lid over fuel pump hole (complete Sat 13.05.2017).
227. Connect fuel vapour carbon canister (Sat 03.06.2017).
228. Pod filter shroud (Sun 15.10.2017).
229. Passenger side exterior rear view mirror (Sun 15.10.2017).
230. New handbrake intermediate cable and assemble handbrake (Thu 26.10.2017).
231. ADR compliant three point seat belts (Mon 20.11.2017).
232. Reinstate original Chev brake booster (Sat 09.12.2017).
233. Plumb crankcase ventilation into inlet (Sun 10.12.2017).
234. 1-1/8" bore master cylinder (Thu 28.12.2017).
235. Source a hydraulic brake booster (arrived Fri 23.02.2018).
236. Source AN fittings and hose for the hydraulic brake booster (Mon 26.02.2018).
237. Fit hydraulic brake booster (Mon 26.02.2018).
238. Engineering Certificate received (Wed 14.03.2018).
239. Blue Slip received (Wed 14.03.2018).
240. Signed club Classic Vehicle Scheme constitution sent. (Fri 16.03.2018).
241. Club-stamped Classic Vehicle Declaration (1835) received (Sat 24.03.2018).
242. ACMC-stamped Classic Vehicle Declaration (1835) received (Wed 28.03.2018).
243. Conditional Rego - Classic Vehicle Scheme (CVS) for Modified Vehicles (Thu 29.03.2018).
244. ECU Tune (pick-up Fri 11.05.2018).

J

New Tailshaft

That's more like it...





Hardy Spicer
3.5" OD tailshaft
chrome moly slip yoke
1350 series universal joints


Bigger unis meant swapping-out the diff yoke for one that will suit.

Enter one Strange chrome moly 1350 series yoke to suit the GM 12 bolt, supplied by Rocket Industries...



Active Automatic Transmissions in Blacktown came good with a new automatic transmission tail housing, bush and seal.

Handed the goodies over to NAS Automotive; they connected the trans to the diff again and reconnected the exhaust.

The last piece of the puzzle was straightening and repairing the floor pan which was taken care of by Platinum Autobody Smash Repairs in Wetherill Park.

Phew!

J