1991 Chevy Blazer (K5) Build

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cowboy-denny

2016-04-14 at 1:50 pm

1991 Chevy Blazer (K5) Build

Here I’m attempting to track the process of the build on my 1991 Chevrolet Full Size Blazer (K5) **Last year they made the removable top.

Story starts: April 14th 2016

Just pulled in the driveway and parked the new Blazer. Had fun going through Memphis then down to Tupelo, MS to pick the K5 up then headed to Nashville for the day and night then home bound on Sunday. Sunday was a long drive in a truck I wasn’t familiar with but it ran good. Max speed was 80 comfortably and horsepower wise or that 700R4 would have to keep downshifting to please my demand for power.

So I didn’t realize how bad the interior was, its not so good. Dash pad is cracked, sliced and butchered. It appears they were trying to replace the speakers maybe since those are the only areas that are hacked. So new dash pad is required. Driver side seat back support is broke so you have a gangster lean to the right if you want to or not. So new seats are needed. Nothing else major except I want to change the wine color to all black which means a complete replacement of the interior which is going to be hell and expensive but look bad ass. Maybe even use billet for accents.

+6 more photos

cowboy-denny
2025-05-03 at 2:24 pm

Engine is out and now getting new engine ready to go in

Since headman headers are on back order until sometime in October and I’m not waiting that long, moved to Hooker Competition Headers
cowboy-denny
2025-05-03 at 2:24 pm
Waiting for parts to show up today to continue project.

Things to do:
- Headers Install
- Fuel Pump Upgrade in Tank (full tank of fuel)
- Install new DUI distributor
- Install EFI Computer and run wires
cowboy-denny
2025-05-03 at 2:24 pm

Headers on and throttle body on. But have to mount fuel injection computer and fuel pump install.
cowboy-denny
2025-05-03 at 2:25 pm

So it runs great but doesn’t move worth a crap. The stall converter is way to tall (3500rpm) is just too much for this rig. Blazer is at unlimited offroad to hopefully reduce from 3.73 to 4.56 and hoping that will help but I imagine I will need to get this back to Frayleys and get a lower stall like a 2800.

Currently, its not fun to drive and the exhaust needs to be fixed… $325 at Muffler Man in Lapeer for some Flow Master Super40’s on a full exhaust from the hooker headers back… which is a good deal. Have to wait for axle repair first.

Thinking of doing away with the sway bar due to going to high steer setup the sway bar is in the way

Also apparently Hutchinson is out of product so they are waiting for a shipment to come in and they have no ETA. We are 5 of 20 waiting in line. Looks like I may have to get some cheap steel wheels for now.
cowboy-denny
2025-05-03 at 2:25 pm

Did a check on status (anxious to get some driving in before snow)

axles are almost done when with 4:56 gears from 3:73

The front Dana 60

The rear GM 14bolt

I’ve been told they will be installed and ready for the road by 10/17
cowboy-denny
2025-05-03 at 2:31 pm

Not starting this yet but I need to fix the gauges in my K5 but having trouble finding the bezel for a 91 as well as gauges.

Here are some options I found on the internet

LMC Truck has these New Vintage Gauges (made in Detroit) that I really like the looks of. It gives me a sense of factory look

I have used Digital Dakota in my 72 cutlass and they looked pretty good and worked but what a pain in the butt to install. Lots of wires for the module, the actual back of the gauges was a cat5 cable. It just took a long time but everyone swears by Digital Dakota gauges and what is mentioned most is the lifetime warranty.

And I think my favorite from Digital Dakota, the HDX option

What’s your opinion

A. NVU

B. Digital

C. VHX

D. HDX
cowboy-denny
2025-05-03 at 2:31 pm

Driveshafts are ordered from Tom Woods.. Hopefully here by Thursday.

Just learned front end Dana 60 is from a dodge
cowboy-denny
2025-05-03 at 2:32 pm

High steer is done. Waiting on speedy sleeve, different calipers, exhaust (super 40 flow masters, center in and out, Kelly is doing the work) driveshafts are in.

should have it back Wednesday to go to the exhaust shop
cowboy-denny
2025-05-03 at 2:33 pm

Exhaust is on (sounds good but a bit louder than expected with the Flowmaster Super 40’s)

Still have Transmission issues even after it spent a week at Frayley’s… they did discover the torque converter was shot so the new Hughes 3 stage is working good in comparison.

Trans Department I need to figure out where the leak is coming from since I’m seeing drops of trans fluid on my garage floor

Engine Department I need to get some help figuring out how to tune the Holly Stealth Terminator EFI (apparently its more difficult than predicted)
cowboy-denny
2025-05-03 at 2:33 pm

Ordered a spare tire cover custom for GearCrushers
cowboy-denny
2025-05-03 at 2:33 pm

So an update.

Engine

Learned that the performance issue was due to not getting the required 43psi fuel pressure to the fuel injection. Why? It appears the tank was rusted up pretty good inside the tank. Flakes and rust scales were attaching to the sock and restrictin that needed fuel pressure.

solution:

upgrade tank from 25gal to 31gal which included replacing sending unit as well as replacing fuel pump and fuel filter in the event it got any of that dirt/rust from tank.

Transmission

So very disappointed in Frayley Transmission in Pontiac. They use to be the shop to go to for transmission work but this trans is been there multiple times and every time I have issues.

1st time it was a bad torque converter

2nd time it was something to do with lockup not working so he drilled a hole? It took more than a week to fix.

Now it’s throwIng fluid everywhere… So gotta go back.

Suspension

Unlimited Offroad needs to work on axles. Horrible vibration when u r moving. Some say that you need an angle on the driveshaft and that it can’t just go straight in. Simple fix would be to change the shim

Some think it’s back lash is set incorrect

Unlimited said motor mounts was the issue but no one else can see that issue
cowboy-denny
2025-05-03 at 2:34 pm

The UD1 front Bumper for DIY4x with a mock install and now it needs to go get powder coated the satin black so it matches the back.

some negative comments on the 2″ square holes. This was suppose to be for lights but the angle is wrong for flush mount. Hole is to small for any square light. Looks like I’ll be using it for hi-lift jack mounting point instead and coming up with something for my lights.

On a side note, the hutchinson bead lock rims came in. Obviously they’ll look way nicer on the K5 then in the box.
cowboy-denny
2025-05-03 at 2:34 pm
So, somehow the K5 got pushed back in line and hopefully they’ll look at it tomorrow. They are still waiting for the front bumper to come back from powder coating but they need to fix the vibration that could be from the rear brake caliper even though I have a feeling the issue is more in relation to the driveline but we’ll find out.

Once the K5 is in the garage, items that need to be accomplished:
1. Fix rear brake caliper
2. Fix Vibration (especially at freeway speeds)
3. Mount the 37.5″ KO2’s on the 5 Hutchinson Rims
4. Mount the new Powder Coated Front Bumper
5. Install the 12,000lb winch which includes remote module and hard wired to dash
I’ll need to bring the truck down and get the old ProComp Rims and old front bumper.

Motor mount drivers side is hitting frame. Dealership no longer can get part but did tell me replacement part number is 14071967
cowboy-denny
2025-05-03 at 2:36 pm

Front Bumper has been powder coated and winch installed. Still need to move box to engine compartment but it requires more wire.
cowboy-denny
2025-05-03 at 2:36 pm

Transmission shop had it for a week. They replaced the trans with another 700r4 rebuilt trans and same vibration at 3rd and 4th.

They also replaced everything in the np241c transfer case to include a new chain. Only thing not replaced is the output drive. They looked for a replacement transfer case but since this is a one year only transfer case (passenger side drop and VSS included) it’s a difficult task which they couldn’t accomplish.

So transmission shop is done.

When I got the truck home, I had a weird thought if it could be a wrong flex plate. On the GM 383 engines it has to be an externally balanced flex plate so I popped the cover off and see it is externally balanced as it should be.

so I looked all over Craigslist and eBay for a replacement transfer case for a 91 which would have the VSS. Found some maybes and then I ran into KodiakTruck.com and he had one. With shipping it cost me around $900 but I have a solid case on the way.

Will keep you posted. If this ends up being a fail then my next move is a new monster transmission which comes with a new torque converter which would be the last two items to replace then it’s back to Unlimited to check axles and drive shafts, again, only if issue is still there.

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