My 2003 Build

RINNY · Post by **RINNY** » Thu Sep 24, 2015 11:49 am

2003 chevy Astro AWD 110,000 / donor vehicle 1999 chevy Astro AWD
Doing this from memory my list isn’t here rite now.
Removed rear-end / fuel tank / muffler and tail pipe
Needle scaled and some welding as nesc / pixlex 20 / zero rust up to transfer case mid ship and front fender wells on sides
G80 Rear with new backer plates / seals / repositioned shock mounts
Rear springs 4+1 rated at 2100lbs ea
Hangers and shackles from Journey
Monroe sensitrac shocks
New ebrake cable
Heavy duty trailer hitch (donor vehicle)
New fuel pump
New fuel lines to engine
New tank shield
2” pucks
Reindexted keys
Replaced and Lowered upper ball joints
Replaced drivers side wheel bearing and lower ball joint
Remaned axels
Replaced radiator support ( big PITA)
Water pump
a/c lines
some brake lines
serpentine belt
front shocks Monroe sensitrac
center roof console and lighted visors (donor vehicle)
lock actuators as needed
flushes fluids filters and complete tune up. I will review my spread sheet and add the stuff I forgot.

Captn. Crunch · Post by **Captn. Crunch** » Thu Sep 24, 2015 3:36 pm

Good look'n van Sir!
I like what you've done so far-good job. It looks a lot like mine actually. I've got a date with a needle gun myself. Keep up the good work and don't forget pics lots of pics!!

RINNY · Post by **RINNY** » Fri Sep 25, 2015 10:16 am

Thank you. Everywhere I go I get spectators, its pretty funnie.. Everyone loves the van. Really didnt want to attract that much attention but it is nice to see people appreciate it. Now I have to put a v8 in it. This winter I will drop the transfer case, Trans , front diff, and take the motor out to finish the restore on the undercarrage. That woukld be a perfect time to put the v8 in it. I had it out in the sand yesterday and I definatly need more HP. I hope to get some input from this site on the easiest swap to do with the most HP and the best fuel consumption. I coukld have never gotten this far without all the great information I got from this site and Mike at Journey. Thanks again!!

Captn. Crunch · Post by **Captn. Crunch** » Fri Sep 25, 2015 3:50 pm

I'm no authority on V-8 swaps as I have yet to do mine. I have started collecting parts that I'm going to need tho. The 5.7 vortec in a year similar to your van is supposed to be the way to go. The 4.3 is a 5.7 with two cylinders lopped off. All accessories bolt up. Things you will need-motor mounts, exhaust manifolds and oil pan come to mind. Start reading-it's all here

T.Low · Post by **T.Low** » Fri Sep 25, 2015 9:28 pm

Sweet!

RINNY · Post by **RINNY** » Sat Sep 26, 2015 5:41 am

Thanks for the input.
Oil pan / motor mounts / Exhaust manifolds, can be sourced or do they have to be fabricated?
Also do I need the wiring harness / brain / tansmission?

They stopped making the 5.7 in 2000?
My astro is a 2003 so do I go with the 5.3?

Captn. Crunch · Post by **Captn. Crunch** » Sat Sep 26, 2015 7:18 pm

No really - start reading
http://www.astrosafarivans.org/bb2/view ... =70&t=3517
And keep reading
http://www.astrosafarivans.org/bb2/view ... =70&t=8622
And then read some more
http://www.astrosafari.com/viewtopic.php?f=42&t=10761

RINNY · Post by **RINNY** » Sun Sep 27, 2015 7:10 am

I have read all those threads a few times..............I scared...........LOL.
I have a shop out here in Rhode Island that says they will do it between 5 and 6K. Thats all well and fine but I definatly have to read alot more and understand it all so I can make sure they are doing what they need to do. I don't want anything hacked up or not done correctly. Either way I need to get much more educated on the whole process.

Could I opt to cam the 4.3 with a few other mods and get another 50 or 60 HP out of it and be satisfied with that. Seems it would be more within my capabilities to take the motor out have it done and put it back in? I am going to take it out anyway to finish my undercarrage restore.

Captn. Crunch · Post by **Captn. Crunch** » Sun Sep 27, 2015 7:35 am

If you have the room I suggest you get another front clip and built it separate. You can take your time, fit the engine, transmission and transfer case. You can get units from JY for couple hundred. You can built your front end with high quality parts Moog? When done trailer complete unit to your mechanic for an easy swap. Six bolts!
The mock up trans and tc you can then rebuild and you'll have spares or sell. Just thinking out loud but you'll come in WAY under the 5-6k your looking at having someone do it all for you and you'll know all about every piece and part
Where in RI?

RINNY · Post by **RINNY** » Sun Sep 27, 2015 10:50 am

I have a 1999 AWD parts van with fuctioning front diff trans and transfer case. Have not checked the gear ratio on it . That is a 5 lug though with high milage so I wouldnt use anything accept the subframe I dont think. Seeing I am going to drop all that out of my van anyway to finish the restore I might just as well use that and build it in my garage under this winter? This would make me feel alot more comfortable and not so pressured to get it done. My go time is the beginning of May when the stripers get here. Seems more doable for me looking at it that way.

RINNY · Post by **RINNY** » Mon Sep 28, 2015 9:00 am

Just talked to a shop that said they can put an L92 with a 465 tranny into my 2003. He said I should be able to find the package I need for around 3500. The shop is equiped with a machine shop dyno and all the goodies. It will be pushing 465 hP when done. 1500 to 3000 labor depending on what I want to do. so they can fabricate, do anything to the computer they need to, and dyno test to dial it in? Wadda ya Think guys?

Captn. Crunch · Post by **Captn. Crunch** » Mon Sep 28, 2015 6:54 pm

What do I THINK? If you have found someone who can deliver what you want and you can afford to have someone deliver what you want-hand them your keys!
This will be one Safari I GOTTA have a ride in!

ps. I'd like to talk to you about your 99 parts van.

RINNY · Post by **RINNY** » Wed Sep 30, 2015 1:53 pm

revised list:
Removed rear-end / fuel tank / muffler and tail pipe
removed all plastic trim cleaned, painted, and reinstalled
Needle scaled and some welding as nesc / pixlex 20 / zero rust up to transfer case mid ship and front fender wells on sides
G80 posi Rear with new diff cover,brake backer plates, and shoes / seals, synthetic fluid / repositioned shock mounts
Rear springs 4+1 rated at 2100lbs ea
Hangers shackles , bump stops, rubber brake line from Journey
Monroe sensitrac shocks
New ebrake cable and adjuster
Heavy duty trailer hitch (donor vehicle)
New fuel pump
New fuel lines to engine
New tank shield
2” pucks
Reindexted keys
new front brake pads
Replaced and Lowered upper ball joints
Replaced drivers side wheel bearing and lower ball joint
Remaned axels
synthetic front diff fluid
Replaced radiator support ( big PITA)
Water pump, thermostat, and hoses
a/c lines from condenser to rear 1st section
silicone vacume lines
some brake lines
serpentine belt
front shocks Monroe sensitrac
center roof console and lighted visors (donor vehicle)
wiper blades
new front fenders
replaced hood ( donor vehicle)
replaced drivers door rocker panel
lock actuators as needed
oil pan and tranny pan gaskets, tranny filter
hummer rims
Goodyear Duratrac Wrangler 235/85/R16
4 wheel alighment within all factory tolerances
ALL flushes (Including kerosene motor flush) fluids, filters, and complete tune up.
all clips ties and chafing protection as needed
reconditioned all lights and lenses
between 400 and 500 hours!! ( hey its my first run at doing anything like this.......waddaya expect!! LOL)

RINNY · Post by **RINNY** » Wed Sep 30, 2015 1:54 pm

Any idea what this truck is worth at this point?

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My 2003 Build

My 2003 Build

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