8.1l/ 6speed manual swap into 86 crew cab 4x4

[bohrer54]

Hi guys, i have some question to throw around at you. Sorry for not knowing where to post, but in searching really havent found the info i need.

What i have is a 86 crew cab 4x4 4 speed with a shot motor, and a 2004 k3500 4x4 with a 8.1 and a 6speed manual with a wrecked body. my question is should i pull out the 8.1, 6speed out, and install into the old chassis and retro fit anything else i can salvage from the 04.

or pull the body off and install the cab, front clip and box on the 04 frame.

I a leaning towards the new chassis old sheet metal due to the upgraded steering, suspension and brakes ,just not sure of how much fabbing needs to be done to make things line up and bolt up.

I am a welder/fabricator by trade so i am not afraid of the cutting, welding, and fabrication of things. Either way there will be a few hurdles but in the end what i hope to have is a nice driveable tow pickup, with the ultra cool 6 speed.

If i could get some opinions of yours on what would be better, easier, cheaper, or even possible that might make my decision easier.also any  refrences to people who have swaped either way would be helpful. thanks in advance.

[beastie_3]

Swapping the motor should be easier than body. If you fabricate, then both should be free, or close to it.

[nucknoel89]

I'd say put the 86 body on the new frame.  The engine, tranny, etc. is already mounted, wired, and running.  Plus like you said you can enjoy the benefit of better steering, ABS, etc.

[Grim 82]

It would be easier to put a new motor in the 86 and a new body on the 04 and have 2 trucks  
Swapping the motor to the 86 would probably be easier than swapping the body, but either way most components in the vicinity of the firewall would have to be retrofitted to the older body style. Swapping just the drivetrains would save you the work of messing with the brakes, steering column, HVAC, etc. And, you would earn alot of style points around here for a 8.1 6-speed crew cab. People here have done crazier things and they can help you out.

[SMiller]

Swapping the motor\trans. is so fast and simple I would go that route! They make stand alone computers for the 8.1 so super simple swap. Part the rest of the '04 out to pay for the project.

[bohrer54]

Thanks for the info guys. i did measure the track width on both pickups and found out they are a lttle different and think it might be easier to put the drive train in the old pickup and use as much off the 04 as i can.

Can i have the 04 computer reprogrammed to eliminate alot of stuff not needed. how about the wire harness, does it need to be custom made. should a guy try to custom fit the new dash into the old pickup so the speedo, warning lights and guages work, or try to get a aftermarket dash kit? Sorry for all the questions.

thanks

[Captkaos]

you don't need to reprogram it if you are swapping the whole drivetrain straight over.  You will probably want to remove some of the unnecessary wiring in the harness though.
An aftermarket dash is the best bet.

[bohrer54]

would the transfer case work as well, it is a manual shift one? other than maybe the front shaft i can get one modified for that.

[SMiller]

You don't want the trans. case that came with the 8.1 unless you are going to do a fix kit on it while it is out, they are known to have a clip get eat through the case, bad design. 205 case for me! I don't know if that would bolt onto the ZF though, worth making some phone calls over, try advanced adaptors.

[bohrer54]

thanks i will look into it some more.