I haven't driven the car since July 4th, 2015. I remember the date because April and I went for a drive that day. I attempted to cross a creek which I'd crossed many times before, but I didn't realize they had just grated the rock bottom the day before. We didn't make it. When I later pulled the carpet and insulation to let it dry I found that the passenger side floorboard had been holding water from a leak. I've kept the car covered since that time because I knew I'd have to pull the fender to fix the leak.
April's cell phone got wet and the front screen still doesn't work. The worst part was diving under the car to hook up the tow strap.
The first order of business was getting the car to my house. I had it at my fathers house and it was pretty solidly wrapped up. It took several hours to uncover it and put a battery in it and fill it with transmission fluid and get it running to bring home.
I had blown the original 305 on the way to Baton Rouge in 2005 to be a part of The Dukes of Hazzard movie (pictured below: semi-functional dixie horn). This replacement is a stock 350 that was a warranty issue from GM. Back when my family owned a GM dealership, someone ordered a new truck sometime in the early to mid 80s and GM put the wrong timing chain on it. The people demanded GM give them a new engine, so this one was practically new and had been on an engine stand for years. We dropped it in and it served as adequate, anemic motivation for 13 years, although a somewhat hacked together hodgepodge of 78 305 and 80s 350.
I was planning on purchasing a totaled vehicle and getting the engine and transmission and all other needed components at once, but first I contacted a guy I had previously bought a 2003 5.3 from several years ago. He seemed like a really solid guy and when I asked him if he had another 5.3 he said yes. We arranged for the purchase and then he stopped answering my calls. After a week and a half I began to realize he was being a flake. It's not so much the engine that bothers me as much as the fact that I've had several situations lately in which people just won't follow through, do what they say they'll do, or show up when they're supposed to and this instance was just icing on the cake. It's difficult to try not to be bitter when you have numerous run-ins with people like this. Because I thought I already had an engine I needed a transmission. I had a friend put out the word and he found a friend of his that had a 4L60E he wanted to sell. I contacted the guy and we met that weekend and I purchased it. Now I don't need to buy and engine and transmission together, though I think that would be easier.
Everyday after work I've been coming home and working until or past dark getting the car ready to pull the engine. These have made for some very long and tiring days. One of the most time consuming parts is continually jacking up the car to access the parts I need. I'm having to keep the car blocked as much as possible because I live in a neighborhood with a bunch of older, retired people and they have continued to call codes on me time and time and time again. I had to sell a '63 Corvair project a couple years ago because of that. America: The Land of the Free.
It's been quite a while since I've worked on things from this time period. Fortunately, some things did come back to me after some thinking, like how to remove the U-joints from a GM driveshaft.
Fortunately, my long time friend who also works with me offered to come over and help when the engine was ready to come out, so after work one day we came straight home and yanked out the old 350. It went surprisingly smooth. Because our daylight is so limited after we get off work I made sure to have everything disconnected and ready to yank out as soon as we got there. The last time I pulled an engine and transmission bolted together it was a 1960 Cadillac 390 mated to the original hydomatic and a bolt broke and the engine fell. I know there's nothing special about a small block 350 and a 350 turbo, but the 390 experience was like touching a hot stove and I was paranoid it was going to fall at any moment. Grade 8 bolts are therapy for overcoming past trauma.
The exodus was without much fanfare and I tucked the old motor in the bushes with a tarp over it. I plan to weld up an engine stand with some large rubber wheels so I can roll this unit into a dirt-floored barn until I'm able to build a shop.
One thing I hate more than anything when working on cars is looking for a tool I know I have and not being able to find it. I hate it; With a passion. This results in more trips back to the workbench, but not spending 10 minutes looking for lost 14mm wrenches.
April totaled this car a few years ago. It was captial-T boned in the rear when she pulled out in front of someone. The impact broke the sealant loose in the windshield and I suspect also caused the seal to begin leaking where I had previously fixed a leak in the passenger floorboard. Though I fixed this leak the last time without removing body panels, I knew to really clean out the area and fix it properly I needed to remove the fender. It was over 100 degrees the day I removed the fender and the fender was so hot I couldn't touch it with my bare hands. Fortunately, the humidity was only 340% that day. I long for the days of having a shop and working in the shade. Not pictured: my small in stature but mighty in force squirrel cage fan keeping me from passing out.
I have to keep detailed notes on where all the bolts are located and how many shims they have or I'll never be able to get things back together. I keep photo evidence of most bolts but I make diagrams for body panels. I am envious of people who can throw everything in a big box and then get it all back together later, however I really can't stand digging in a box full of bolts hunting for what you need. I label everything and put it in a ziplock bag so I know exactly where everything is exactly when I need it.
I am absolutely, entirely out of space for storage, of anything.
Dad came over and worked the water hose as I lay down in the car hunting for the water leak. As I suspected it was the area on the far most passenger side of the HVAC box. Here's the plan for this car. I have a complete and very solid roller parts car with perfect body panels that I bought several years ago. Later, when I have a shop I plan to take this car down to the frame and and at that time I'll pull everything apart. For this season of life, I need a daily driver that unfortunately is going to have to sit out quite a bit. I'm afraid if I pull this box off I may open up a can of worms and destroy my deadline so my plan is to reseal the leak without removing the box. I'm unsure yet what I'm going to use to do so. The area of note is between vertical, left side of the cowl and the blower motor box. I cleaned and scraped all of the old silicone.
Because my original gas tank was not made for EFI, it does not have any baffles in it. Because the Caprice and Impala is the exact same car from 1977-1996, just with different bodies set on top, I was able to get the 1995 Caprice gas tank, the straps, and the heat shield from a junkyard because those cars came from the factory with EFI. Dad made some calls from his old contacts and found the tank and made the 100 or so mile trip to go get it one day while I was at work. These tanks are plastic and have baffles and fit perfectly into my car with zero modifications. I scrubbed it down because it was very nasty.
And as luck would have it, my old tank was well over half full. At least I remembered to jack it up before I let it fall on my head.
Next I removed the old engine mounts. Fortunately, LS engine swaps have become so popular that many parts exist now to help put these engines in a wide array of older cars that never came with them. I bought a kit online that is supposed to bolt right into the existing bolt holes for the engine and transmission mount and keep the correct drive line angle and spacing for a 5.3 with a 4L60E. I will need to switch to a lower profile oil pan and change out the exhaust manifolds to fit between the frame rails. The mounts came out without too much trouble, but a slightly large access hole for the bolt heads hidden inside the frame would have been nice. I suppose that's too much to ask considering GM couldn't even decide on which type of bolt to use, as half are metric (spit) and half are standard.
