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Semi Sloppy Reg Cab 1500 Stepside Turbo Build

Old 11-26-2018, 11:15 AM
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Picked up an 8.8 rear out of a 1994 Mustang. It's a 2.73 with a limited slip carrier, obviously we'll be doing a gear swap on this thing! I'm thinking 4.10s. Unfortunately it didn't come with calipers or brackets but I already snagged a set on ebay. I also ran to the junkyard and grabbed a set of 5 spoke wheels off a 2003ish Explorer that oddly enough look very similar to the factory Silverado wheels.



Also tossed in a $40 ebay intake - simply remarkable how they can include all these decent quality pieces for so little - gotta love that cheap overseas stuff.


Next up - electric fan swap to free up some room under the hood. I snagged a set of '99 F-Body fans in the junkyard and will be wiring up my own relay pack to drive it all.
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Old 12-03-2018, 10:45 AM
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Over the weekend I finished up the e-fan swap to free up some space under the hood. I used junkyard fans from a '99 V6 Camaro and made up a couple brackets to hold it in place. They're controlled by 3 relays that switch from series to parallel and are triggered by the PCM for seamless operation.

I removed the grille to scope out the space for the intercooler, definitely will need to trim the hood latch diagonal bars.


The bed makes for fantastic parts storage
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Old 12-17-2018, 03:52 PM
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Got some things knocked off this past weekend. Installed the 4L80E Transgo HD2 shift kit, took me about 2 hours going very slowly and cleaning as I went. Very simple as long as you stay organized. The fluid in the trans looked bright red and new. I was told it came out of a fleet truck, 2500 crew cab that was used by the highway department here in NYS.









Fresh filter and RTV'd the **** out of the pan to prevent future leaks. Hopefully I never have to open the trans again!


Finally I temporarily plugged the cooler fitting holes (which reminds me, I need to buy new fittings) and power washed the whole thing to get the road grime off it.


I still had some time left over Sunday after the Bills game so I pulled the 8.8 into the garage and hoisted it up onto my custom inspection stand



So this came out of a '94 Mustang...the story is that this rear end was removed and replaced with a new one in order to try to solve a vibration issue but ended up not being the problem. It sat in a guy's shop for 20+ years with what looks like the original fluid in it. I would bet there was some minor moisture that mixed with the oil because what came out looked like baby ****. Luckily there was no corrosion on anything, everything was still oily.





I let it drain for a while which made it a bit less messy to work on


Pulled out the axles (which are equal length), since this didn't come out of an explorer I won't need to shorten one side. All the bearing caps, bolts, and shims were otherwise bagged and tagged, and will be reused wherever possible.


The Denmah turbo kit is in from VS Racing, Billet 7875, 80lb injectors, etc etc. I have some time off coming up over the holidays so I'm going to try to smash out as much as I can in that time.
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Old 12-17-2018, 03:58 PM
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Nice! Keep up the good work and keep posting. I'm especially interested to learn what it takes to adapt the 8.8.
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Old 12-17-2018, 07:48 PM
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I just did an explorer 8.8 into a squarebody. all I has to do was move the spring perches out 1.5" per side (i think) and lip the hard line around on the axle so the axle to frame brake hose was on the pass side
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Old 12-17-2018, 08:41 PM
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Why are you swapping the stock 8.5" for the ford 8.8"? Why not just do put a good diff and gears in the stock axle?
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Old 12-17-2018, 09:11 PM
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Originally Posted by truckdoug View Post
I just did an explorer 8.8 into a squarebody. all I has to do was move the spring perches out 1.5" per side (i think) and lip the hard line around on the axle so the axle to frame brake hose was on the pass side
Yeah, it should be an easy swap. Besides new brake lines I don't think it will take much to make it work, proabably move spring perches too. Haven't measured yet. Kinda plan to just drink 100 beers and grind and weld until it works.

Originally Posted by onebadbowtie86 View Post
Why are you swapping the stock 8.5" for the ford 8.8"? Why not just do put a good diff and gears in the stock axle?
8.8 is stronger than the stock 8.5 Gov-Lock 10 bolt which is affectionately known as the "Gov-Bomb". By the time I bought a limited slip and ring/pinion for the 8.5, I could have a fully built out 8.8 with a gear swap.
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Old 12-17-2018, 09:27 PM
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Just curious, seems like it would be easier to just put a good diff and gears in the 8.5. With a good eaton or trutrac diff the 8.5's are pretty stout.
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Old 12-19-2018, 07:44 AM
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The parts are really rolling in now, I have 2 weeks off coming up and really want to hammer out as much as possible over the Christmas break

Wait, huh? WTF is this ****?


PHEW, that was a close one.


Got these wired up, just need to clean up some wiring. If I ever want to run "stealth" mode I figure I can cover up the gauges with an orange camo trucker hat...


I have one of these in the mail too along with a bunch of v-bands, flanges, etc. Figured it wasn't worth my time hacking up a passenger side manifold, getting nickel and dimed on v-bands and clamps and bends, and having flow issues down the road. Jeg's had it on sale for $270, can't beat that...

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Old 12-19-2018, 09:52 AM
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yeah that mani really is a good deal. I plan on trying one soon
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Old 12-20-2018, 02:54 AM
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why are you swapping in a 8.8?

Done close to 1200 wheel on the 10 bolt with an eaton tru trac and upgraded axles... or you could do a 14 bolt from a escalade or SS and be good for BIG horsepower and bolts right up.
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Old 01-07-2019, 01:31 PM
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So the holidays came and went. Lots of good things came:



Including a new daily to replace my Pathfinder. It's a 2009 BMW 335i Xdrive, 6 speed, Space Gray over Saddle Brown, heated seats and steering wheel. It's getting DCI and MHD tune, and nothing else besides maintenance.







Finished the install and setup of the 4.10s with the 8.8. All existing shims were reused, looks like I got a nice pattern, and backlash came to .011".







Gotta sign your work!


I did mock up the 8.8 under the truck, going to have to run spacers if I want to use the Explorer wheels that I have. I may even switch them out to some lower offset wheels to buy even more breathing room since I don't have much space between the insides of the tire and the leaf springs.

Also drained the cooling system and removed both stock manifolds, of course there is 1 bolt broken off flush in the very back of each head. They shouldn't be too bad to remove with the MIG. I have a feeling the AC compressor will not fit with the Hooker turbo manifold on the passenger side. The upside to that is I can ditch the factory condenser to make room for the intercooler.

More to come.
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