It No Fit...

[astrovan98]

My van is a 1998 Astro, 2wd.

[mdmead]

My van is a 1998 Astro, 2wd.

I was pretty sure it was a 2wd based on what you have said of the install... but just wanted to make sure as if it was an AWD, I'm obviously doing it wrong as I have all sorts of clearance issues!

[astrovan98]

I think, judging from your pictures at the beginning of this post, that you put the black plates on the wrong sides. If you look at the picture where you have the engine sitting in the chassis, and the drivers side mount sits too far back, then look at the second picture from the top, you will see that there is a tapped hole towards the rear on the black plate that is not being used. If the black plates were switched form the right to the left side, the tapped hole would be at the front of the engine, and likewise, the steel mount would sit farther forward, aligning the arms with your rubber mount.
Try switching the black adapter plate from the right side to the left, and vise-versa. Then put the mounting plates back on.
Let me know if this works.

[astrovan98]

Try this site I captured early in my build. It is a fellow that did an AWD Astro conversion. It has many pictures and details that you may find helpful.
http://www.aei.ca/~nmaclennan/index.htm

[lockdoc]

That's Neil. He is a member though he hasn't been on in awhile other that to post parts for sale since he sold that LS1 AWD van.

[rlsllc]

You know, swapping in a Dana 44 or 60 front axle would fix the clearance problems on the front dif and axle mount.

[mdmead]

I think, judging from your pictures at the beginning of this post, that you put the black plates on the wrong sides. If you look at the picture where you have the engine sitting in the chassis, and the drivers side mount sits too far back, then look at the second picture from the top, you will see that there is a tapped hole towards the rear on the black plate that is not being used. If the black plates were switched form the right to the left side, the tapped hole would be at the front of the engine, and likewise, the steel mount would sit farther forward, aligning the arms with your rubber mount.
Try switching the black adapter plate from the right side to the left, and vise-versa. Then put the mounting plates back on.
Let me know if this works.

Thanks! I'll double-check them. One set of the mounts I had instructions for, the other I didn't. I tried one set two ways and it only came close one direction, but I don't recall which mounts now. Even if they are wrong, I can see I have a width problem (basically the thickness of the LS to SB adaptors) using both sets of mounts. (This wouldn't be hard to fix though.) The other problem is there is no way the engine can sit down without pan modifications. Since I planned on doing a subframe lift from the beginning anyway, I'm not so worried about tucking it down in. If I can get by raising it 2", this would still give me 3" of clearance up top for any top end issues and raise my pan up away from rocks and stumps(!)

Yes, I e-mailed Neil early on regarding his swap and have looked at his site several times.

[mdmead]

You know, swapping in a Dana 44 or 60 front axle would fix the clearance problems on the front dif and axle mount.

Yeah, yeah, but I don't really want a solid axle front. I like the factory ride and suspension just fine. I just want a vehicle more capable than stock.

Now if I ever move on to a 6.2L diesel swap into an early van, then it might get a Dana 44.......

[astrovan98]

On my 2wd project, I used the truck pan and it fit perfectly, although it does sit about an inch lower than the engine crossmember. It does have extra oil capacity however so that's a benefit. I will most likely keep the deeper sump, and build a reinforced steel drop plate on the crossmember to protect it. My crossmember didn't quite touch the ground when I aired-out the suspension, but with the extra plate it probably will now. The suspension was designed to drop the truck so the front bumper ground effect package and side skirts would come within 1/4" of the ground on level pavement.
From my investigations, I think you would be cutting little bits out of the pan anyway for the 4wd version.
I have seen the solid front axle method on a couple of trucks, and they looked pretty good, especially with the appropriate large terrain tires, but this is a look you may not fancy.