Chevrolet and GMC "K-van"

General info.

     Pathfinder GM conversions all have leaf spring style front suspensions. With the fixed spring hangers at the front and the shackles at the rear. The shackles were formed from a single plate of steel, flame cut  and shaped to resemble a capital "H".  The bolt holes are 9/16 diameter with a center to center measurement of 4 inches.. All full size GM vans used weld on sub frames that were pre-assembled with hanger and shackle  mounts. These pre-assembled sub frames were then pressed up into the OEM frame horns, and welded in place.

    Nearly all GM units used a Dana 44 front axle with eight lug GM 3/4 ton wheel ends.  It is a common misconception that G30 and GMC 3500 units, being 1 tons, should have a Dana 60 front axle. Only a few special ordered vans were built with the Dana 60 axle.

    Chevrolet G10, G20, Astro  and GMC 1500, 2500 and Safari series used GM ½ ton wheel ends much like those used on GM ½ ton trucks, Blazers and Jimmys. The rear axle was left with the smaller 2wd wheel pattern, and a custom made aluminum spare wheel was built  to fit both the 6 lug front and 5 lug rear. Common gear ratios are 3.08, 3.42 and 3.73.

    All vans have a custom engine cross member, since the OEM cross member is an intricate part of the 2wd  front suspension. The first style was built from D.O.M. tubing. Later versions were made from heavier steel plate. In most cases the stock engine motor mounts were reused.

    All vans had their exhaust  systems heavily modified. Custom "Y" and "S" pipes were built to reroute the exhaust around drive train modifications.

    The lower mounts that were welded to the rear axle housing had extensions welded  to them which allowed the use of the OEM stock shocks. The front shocks were changed to a heavy duty

shock that no longer matched the dimensions of the OEM shock. 

GM units used Ford style transfer  cases that had a left hand offset. This was accomplished by using a custom extension housing with a coupler that has the GM spline on the female end, and Ford spline on the male end.

    All vans  required a speedometer extension cable to extend the cable to its new location in the transfer case. Average length was 24 inches. Other cables were built to accommodate cruise control model vans.

     Front and rear drive shafts will vary in length depending on wheel base and transmission used. The front drive shaft will always have a Spicer style CV of either 1310 or 1330 series. All vans used Spicer style drive lines, unlike  GM trucks of the same era which used Saginaw style drive lines.

    There are special ordered vehicles with different variations in drive train, such as Full-time 4wd with a  New Process 203  transfer case, manual transmission or Dana 60 axle front axles. These vehicles are rare, but are still found in service.

     For more detailed info concerning parts and descriptions, please refer to the Pathfinder parts manuals.

Why does my van have a Ford front axle?

The front axle housing was custom built to Pathfinders specifications. The center housing of the axle is on the left side to take advantage of the motor being offset  to the right. That is why the axle appears to be of Ford origin. The wheel ends have always been GM.

How can I lift my K-van?

As well as having an upgraded stock replacement spring, We also offer a spring that is approx. 2 inches higher than the stock Pathfinder K-van lift. It can be installed without  any fabrication to the frame or steering. To level the van, you my need to add-a-leaf or install taller lift blocks in the rear.

How can I convert my own GM van using p/u parts?

I have known many individuals who have converted their vans using p/u parts. When using a GM front  axle housing with right hand offset, you need to lift the van higher than a stock K-van, this will be necessary for clearance between the engine oil pan and the front diff. All the necessary components  are available from  Pathfinder 4wd Van Accessories. Such as spring hangers and mounts, shackles, springs, steering arm, drag link and engine cross member and rear lift blocks etc. You will also need to use steering knuckles that are cast flat on top.  This will allow you to install a special steering arm, and cross steer from the 2wd center link to the right side steering knuckle.

How can I center my steering wheel?
Pathfinder drag links consist of two right hand threaded ends. One of these ends is welded to the adjusting sleeve, leaving one end adjustable. In order to make adjustments, one must remove the  adjustable end from its taper and screw the end in or out one full revolution. Of coarse, if you need something in between, you can't have it. The new replacement drag links are fully adjustable with the drag link ends being left  and right hand thread.

How can I change my G10, G20's rear wheel pattern from five to six lug?

Pathfinder Chevrolet G10, G20 and GMC 1500, 250, Astro/Safari  series vans have 6 on 5-1/2 wheel lug pattern on the front axle and 5 on 5.0 on the rear axle, with a spare rim that  was manufactured with both lug patterns.

Remove  the rear axle shafts and have the flanges redrilled to except the 6 on 5-1/2 wheel pattern. One of the  original stud holes will need to be plug welded because one of the new and one of the old stud holes will overlap.  The brake drum can be redrilled as well. A good 4wd or speed shop can perform this modification for a  reasonable cost. Replace all the wheel studs. Refer to a shop manual for the proper differential tear down procedures.