I got a 6.0 TB from a guy here. Old
style pulley (small, with the brown
spring). There are differences in the
PCV fitting and the coolant lines'
fittings.

The PCV fitting can be removed by putting
a #2 Philips screwdriver up it, and just
rotating it back & forth. It's a simple
press fit. I switched the fittings over,
working the '02 SS fitting into the truck
TB the same way until it snugged down.

The coolant lines aren't as easy. Couldn't
get a good grip. I just did the bypass.
I bent the fittings up a little as they
were interfering with the water pump body
below.

I did the epoxy thing, used aluminum foil
to plug the IAC and PCV holes before doing
4 layers of JB Weld over the course of a
couple of days. I baked the whole thing
overnight in the kitchen oven at 250F to
make sure it was well set before hogging
back the excess and doing the porting.

The '02 throttle shaft and plate fit right
easy. Put the plate in and left the screws
semi-tight, gave the throttle a few snaps
to let it seat the plate where it liked best
and tightened them down with a drop of
Loctite for luck. I ground the bump stop
back a bit. until the blade stops just
short of center. It didn't take much, less
than 1/16" removed but that makes about a
1/4" difference in the location of the
blade edge.

Aside from the coolant lines there's nothing
wrong with using these truck TBs on newer
cars, the shaft swap is about 5 minutes'
work. In fact, the 6.0L core and my TB
have the same casting number, it's all
just the fittings that differ.

Idle bumped up about 200 RPM initially, this
doesn't bother me 'cuz mine's lower than I
like (500RPM). It relearned back to normal
shortly with no fooling around. I reused the
TPS and IAC from the car, the ones from the
core were kind of crusty.

Ran it around town tonight, seems like it's
all good. A little more sporty. <img border="0" title="" alt="[Big Grin]" src="gr_grin.gif" />

I figure all told I put maybe 4-6 hours
into this, including the coolant bypass
and bump stop mods. The epoxy buildup took
days, but only 15 minutes at a pop. If you
used the putty like some folks say, that
would be less, but I like the adhesion of
JB when you work it into the surfaces with
a Q-tip - make sure it's down for life.

So that makes the $100-$150 for a pro job
with powdercoating look pretty not-bad,
really (depending on your personal "shop
rate"). I just like doing this kind of
thing.

 

Cool Beans!

Glad it worked out for ya!