My 1995 K1500 Project

Picked up my latest project last week, a well used but not destroyed 1995 K1500. The truck is rust free and has a fairly straight body with the exception of the fender-bender on the left front. It also has transmission issues, it's a 5 speed with the NV3500, and 2nd, 5th, and reverse are out. I plan on installing a 700R4 as I have always had automatics, and this truck is just begging for one as well-equipped and straight as it is otherwise. So far I have been cleaning it up, and getting ready to remove the transfer case to swap out the input shaft, which will be phase one of the automatic retrofit...

As I bought it:








The engine was very dirty, the previous owner had played in the mud:
Before


After


Before


After


All cleaned up under the hood:


I have since cleaned up the interior, and am currently checking out the brakes and fixing the parking brake cable.

Figure I'll need the parking brake once the driveshafts come out ...

Will update as things progress

Aaron

NICE !!!!

Now Aaron something I was just noticing as well... Are you gonna put a slap shifter in there for the auto? Otherwise you need a automatic steering column.

i think u should stick with a 5 speed

Looking good Aaron. A fender, bumper, and turn signal and you should be good to go once the transmission is in.

+1 on the stick.


but hey its your truck. and its a beauty. you wanna see a dirty engine bay?

what ya plans for it?

FaselZ71 wrote:

Now Aaron something I was just noticing as well... Are you gonna put a slap shifter in there for the auto? Otherwise you need a automatic steering column.

I'm going to putting in a B&M Megashifter, I don't want to mess with the column and airbag.

I'm building this into my next truck used to haul my quad on weekends.

Does the AC still work??

doc_auto wrote:

+1 on the stick.

i jus like shift thru gears makes me seem pretty BA lol

In2Trux wrote:

Does the AC still work??

Yep, still blows cold!

AaronK1500 wrote:

In2Trux wrote:

Does the AC still work??

Yep, still blows cold!

Cool
HaHaHa Sorry

Got allot of work done this weekend! Pulled the drive shafts, transfer case, transmission, and all clutch components. I was working alone, and it was my fist time doing anything of this magnitude, so I was a bit apprehensive at times but everything came part the way it's supposed to. In removing the transfer case I could have used a second transmission jack, but I ended up using some old junk electronic equipment I had laying around as a "cushion" for it to land on, and yanked it off the tail shaft. Then while separating the tranny from the engine, I was hoping nothing would shift or drop suddenly as they disengaged. Using an extra jack under the oil pan to help support the engine kept everything in place. Here are the pics:

Tranny on jack:


Transfer case removed:


Transfer case out:


Hole where shifter was - you can see the gears from inside the cab :


Transmission lowered:


Transmission out - end of a long day!


Now that I've got everything out, the next step is to replace the transfer case input shaft with the 27 spline shaft for the 700R4. Stay tuned...

Awesome update Aaron!, and great pictures! Thanks!

Nice work Aaron
If I could only remember to bring my camera when I do things too.
I love all the pics... Well done man

Yes man very well done!!! Doing the job by yourself is a PITA!! Trust me. Great pics though...

lookin good. no surprises. keep it up!

I wish all my projects were that smooth.

Got the 27 spline input shaft ordered and disassembled the transfer case tonight. I got several pictures and will share some tips I discovered along the way. Also, much thanks to FaselZ71 for his advice and pictures of the transfer case breakdown, this gave me a great idea as to how to proceed.

Had to charge the stupid camera battery, so I didn't get pictures of the first several steps, but here goes:

After removing the front input cover and snap ring, removing the rear extension housing, snap ring, VSS sensor wheel, and second snap ring, you the remove the case bolts and separate the case halves. I had been told about how the pump intake pipe is difficult to re-connect, so I made a point to keep the pump and intake strainer and rear cover together as I removed the rear cover. Here is a picture of it removed:



Next thing I ran into was removing the main shaft from the case. I tried unsuccessfully to walk the chain off the sprocket of the main shaft, wanting to avoid having to remove the large nut from the front output yoke to remove the front output shaft. As I was struggling with this I realized there's a snap ring holding the sprocket to the front output shaft...



So off came the snap ring and I was in business:



I was the able to carefully remove the main shaft, front output sprocket, and 4wd clutch assembly:



Parts removed:



Then removed the High / Low selector fork:





Now was time to remove the input assembly and separate the input shaft from the planetary unit:



Planetary removed:





Then I had to remove the internal snap ring on the planetary cage cover and lift out the input shaft:



All done now to just wait on the big brown truck to arrive next week with my part...

Nice pictures.
I love the play by play.. Looking forward to next weeks episode

Awesome step by step! Thanks for sharing! Can't wait to see the rest.

While waiting on my transfer case parts, I went ahead and got the flywheel switched out to a flexplate.

Flywheel removed, was heavy but not as bad as I thought:



Cleaned up the rear of the engine, and the main seal seemed dry and not leaking, So I let a sleeping dog lie on that one. Next I got the flexplate installed...





After this I tried the starter just to make sure everything would engage properly and it works great!

Now to get that transfer case back together next week...

Nice!

looks good.. your gonna have one hell of a time getting all 6 torque converter bolts in.. lol

What kind of oil filter is that? A Baldwin or a Fram?

lookin good. keep it up