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Duramax LBZ H2 Write up

  #1  
Old 03-31-2019, 08:38 AM
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Default Duramax LBZ H2 Write up

I figured it was time someone did a real write up with wiring and part numbers.
So Iíll do a step by step on how to put a 2006-2007 duramax LBZ in your hummer h2
and it look like it came from GM. I might miss a few things but itís pretty simple.
If I have everything ready and ordered I can be done in 1 week Test driving on week 2.
but I rebuild and degrease and paint everything first. So thatís an extra week. If you have
questions feel free to ask. Please no trolls. And this is my first write up. So take it easy.
 
  #2  
Old 03-31-2019, 09:04 AM
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Day one:
Take off Body, that includes gas tank filler, connector for lights in rear under vehicle, batteries, fuse block, hood, radiator,
condensor, 12 body bolts, shift linkage, brake cable, brake cylinder only 2 bolts in front, a/c lines, accumulator. Etc..

keep the condensor, fuse block, body bolts, fan shroud, shift linkage.
The a/c lines and accumulater get use off of donor truck. Scrap off of hummer.
Trash the power steering cooler, radiator and pcm mount.

Roll body out and cut exhaust off and trash. Pull out old drivetrain. And cut off a few connectors to be reused on the swap
to make it look factory when soldering wires. Like the transfer case connector. Etc.. or just solder it.
keep the shifter linkage on transmission. Your going to be modifying it for the Allison trans.

Empty out the fuel tank and cut all fuel lines out and evap canister, 05 and up h2s can have a duramax fuel sending unit
modified and installed. I just take the hummer metal legs and float with wire and swap it over to dmax sender.
04 and older the tank is different so u have to modify the existing sender. I simply cut out pump drill a hole where the return line use to be and insert a 1/2 fuel hose and use the feed as my return. And no other mods. I’ll post a pic of how I do the vent
tubes. Take off filler neck and whole saw out the filler to fit the diesel at the pumps.

12 foot 1/2 fuel line feed
12 foot 3/8 fuel line return
8 foot 5/16 vent line

finish up day one by cleaning and degreasing frame and under body, engine bay. And paint.
 
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Old 03-31-2019, 09:09 AM
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Old 03-31-2019, 09:56 AM
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Day one forgot to say the front drive shift gets tossed and rear driveshaft gets modified to fit Allison trans and lengthened. On Day two u measure rear for length and use front driveshaft from donor truck. And I’m sure a few other small things missed like skid plates and side steps, rock guards, easy stuff u can’t miss. Trash intake, trash coolant reservoir.

Day Two,
Drop in donor Duramax Drivetrain. Before that, take motor mount brackets off of donor duramax truck and toss hummer ones,
cut one inch off the frame mounts and put on the rear to give room for radiator stack. I’ll post pics. The passenger motor mount bracket will have to be modified to fit after that. Then bolt them in. Take off the trans bracket and cut the mount off and reverse it. Then lower the drivetrain down and line up the trans bracket and weld it. Bolt it all down.
Run those fuel lines from the tank from day one and hook them to the donor motor.
Install front driveshaft from donor truck and measure the rear drive shaft length and send to a drive shaft specialist. Bring donor driveshaft to steal the yolk off it to fit Allison.

Install a 4” MBRP exhaust for a 2006-2007 Silverado $270. It fits in pretty dang good. I usually wrap the Exhaust from beginning to end of transmission. For heat purposes, the custom trans lines sit close to exhaust so I also wrap the trans lines with exhaust wrap using metal wire ties.

I use a 1 inch puck on the body mounts just for a 1 inch cushion. Makes a world of difference and u don’t have too. If u do, then u need two longer bolts for the rear body mount bolts.

Lower hummer body body down on frame and install bolts.

Install e brake cable. Plug in rear light connectors, put on gas tank door and cap.
 
  #5  
Old 03-31-2019, 10:24 AM
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Day three,
I knock out the wiring in a few hours, including 4x4 wiring.
Need soldering gun, solder, heat shrink. 4x4 front axle actuator
from donor truck and the 5 pin pigtail, 4x4 buttons from donor
truck as well. I will post schematics later.

Install passenger battery tray from donor truck, cutting and modifying will happen.
Install pcm mount from donor truck in same spot as hummer old pcm mount. Hook back
up steering shaft and plug in power steering lines and brake cylinder, remember power steering
cooler won’t fit.
Install coolant reservoir from duramax donor truck or new. I use new its $85.
install the batteries and lock downs. Heater hoses, accumulater from donor truck.

install pedal and mount from donor truck with harness and toss hummer pedal.
plugs right threw the fire wall by fuse block. Fits only 1 connector. Super easy.
put in donor truck gauge cluster. Toss hummer one. Swap the plastic glass on front.

Modify the hummer shift cable bracket of old transmission for the Allison trans to work
with the hummer shifter. I’ll post pics.
 
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Old 03-31-2019, 10:27 AM
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Old 03-31-2019, 10:32 AM
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  #8  
Old 03-31-2019, 10:33 AM
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Reversed trans mount.
 
  #9  
Old 03-31-2019, 10:58 AM
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Day Four,
Time for the dreaded front end. I use a 2005 lly duramax
fan and fan clutch new $200 and a 2005 lly duramax
Radiator $150 because it’s 3 inches shorter than the Lbz
and fits factory flush, I use a 2006 Lbz intercooler and bolt the
radiator and intercooler together. And cut off everything else I don’t
use on the two, That gets in way of the horns and lines. I cut the bottom tray
out completely and cut the top of hood support bracket to fit condenser
also cut out inner fenders to fit the turbo pipes. I keep taking the stack
in and out and making modifications to what needs cut to fit. When I’m
satisfied. I install condenser in the front and the top radiator support
from the h2 loosely. I then put on the turbo pipes and clamps/ hoses on.
I put upper and lower radiator hoses. All A/c lines. And then tighten down
the radiator support on top, install horns. Use old trans cooler bracket and
cut old transcooler out and replace with a good after market transcooler
I then run garden hose as a measurement for my trans lines that get custom
made. Once trans cooler is installed and custom lines. I fill all fluids, atf, oil,
power steering, coolant I fill and pressurize for leaks.

Go go over every thing in engine bay for clearance and loose wires or bolts.
make sure batteries are connected. I use the stock h2 fan shroud with some
modifications and mount tcm to that like factory. Make sure your all plugged in.

I use HP tuners to disable vats, update fuel tank size, gear ratio, Egr Delete,
using a custom tune to get 500hp. You might have to send yours to a company
and tell them what you want. Definitely disable vats security or truck won’t
start. It will think it’s stolen.

I might be be missing a couple small things.

Start it up. Listen to it and go to sleep.
 
  #10  
Old 03-31-2019, 11:15 AM
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Day Five,
Finish under hood and install and cut hood and anything else, like rock guards, steps, rear drive shaft, anything loose,
skid plates. Etc..

Modify intake, use the 90 degree flex tube, cut out the maf tube off of old intake air filter housing. Use ru-2800 5” k&n filter.
super easy. Vacuum a/c, check for leaks, fill Freon. Remember all the lines, accumulator and compressor are used from donor truck and the condensers are the same. Check over everything and test drive. Fix any issues. I use an autel scan tool
to check my balance rates and trouble codes, temps and pressures. When satisfied. Install hood.
this part you need to be extremely careful. Depending on how u ran your trans lines the hood will need to be cut for that
the a/c condenser and trans cooler. The bumper will have to be cut depending on how you ran trans lines. I run them threw
the bumper. It’s hidden and can’t be seen. And less hood cutting. Then check over everything for the 100th time for loose anything, plugs, wires, etc... you want that hummer better than GM quality.

Assuming everything went smooth. She is done and I’ll get the 4x4 schematics posted, wiring under fuse block, and misc
stuff I missed along with more pics.
 

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