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Author Topic: 3800 NA swap into an AWD Tek  (Read 801 times)
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lonewolf04
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« on: December 10, 2018, 09:45:13 AM »

I read the couple swaps on here for the 3800 SC swap. Never really saw what was done to get the gauge cluster to work, but seems as if the consensus was to keep the 3800 harness and PCM and have it mate in with the Tek.

I am looking at taking a different approach at the swap and only doing the 3800 NA Series II motor and harness and mate this with an AWD Tek transmission. Both of the transmissions from a 3800 NA and the Tek FWD are the same so I am figuring the AWD version should play nice together, the only difference is it will have a PTO on the unit.

From what I saw the only swap people have talked about is the 3800 SC and not working with AWD because of the different diff sizes, hence believing a 3800 NA motor with the Tek 4t65e PTO trans would fix this dilemma. I know I won't be getting as much of a power boost only with a NA 3800 but having AWD will be a nice trade-off.

I found a nice '02 AWD Tek  for the vehicle and will be looking for an '00-02 Grand Prix, Monte Carlo, ect. with a NA 3800 as the donor vehicle.

After the engine swap I am looking to give the suspension a 2-3" lift This will most likely be a glorified "body lift" and using pucks between the front and rear sub frame, along with custom spacers for the struts. Then add some aftermarket wheels and probably around a 30" tire. Trying to make the original vision of the Tek as being "The most versatile vehicle on the planet" more of a reality instead of just a people hauler.

Any info on the engine swap not posted be great. Have been looking around on some other forums for info on specifically the 3100/3400 to 3800 swap. Again, most have talked about the SC swap.
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lonewolf04
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« Reply #1 on: December 10, 2018, 12:58:05 PM »

So I did some more digging into which 3800 to use to make this swap easier. Looking at a 2002 Monte Carlo with the 3800, the vehicles use the same PCM connectors are the same and the pinouts are extremely close. Also, I looked at the instrument panel pinout, which uses different connectors, but has the same Class 2 data line that feeds it, so our instrument cluster should function fine. I am now heavily leaning for a Monte Carlo donor vehicle with a 3800 and make the necessary pinout changes. It seems this donor vehicle should eliminate a lot of grief in this swap.
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Pontiac6KSTEAWD
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« Reply #2 on: December 10, 2018, 01:39:35 PM »

Keep us up to date on this swap.. I want to do this swap on my Tek AWD but dont really have the nerve.. A simpler swap, with an engine that already has the AWD system is a 3.6 out of a 2006 Rendezvous. The only problem I see is drive by wire.
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Brian - Carpe Diem

01 Pontiac Aztek GT OPT AWD 121k - 04 GMC Envoy XUV 182k - 05 Mercury Montego Premier AWD 52k (wrecked)

lonewolf04
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« Reply #3 on: March 19, 2019, 02:08:07 PM »

Well I found a 2004 AWD Aztek that I might be able to pick up next weekend as long as it doesn't sell. Supposedly the trans is having issues and will get anything fixed that needs to be before going into the swap. I don't want to deal with mechanical and swap problems and not know which is which. I reviewed some more diagrams because I know there were some changes in the 4T65 trans between 2002 and 2003+. Looks like if I stick with a 2003/4/5 Monte or Impala with a 3800NA I will still be good with electrical. Biggest thing will be my plan to pull the PCM bin file from the donor vehicle and drop it onto the Aztek PCM, have not done this and will need to get up to speed on software and such. This way my VIN data will stay intact and no PCM/BCM mismatch.

Here's to hoping I get it.
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lonewolf04
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« Reply #4 on: April 01, 2019, 10:06:15 AM »

Successfully got the '04 Victory Red, cloth grey interior, AWD Aztek. According to the build list on this site, only 188 were made that year in this combination. Was extremely sick through the whole experience of getting it and still after the fact so haven't had any time to look at it really good. The vehicle isn't in too bad of shape rust wise, other than the normal rear door opening corners that need some help. Think the rear door seams need cleaning from being up against the rust too. Interior needs a lot of cleaning though. I know it needs new front seat belts as they are fraying from some type of damage it looks like, dog or something. The guy  mentioned he replaced the brake lines with stainless steel ones he bent himself. I haven't looked at them yet, but sounds like it might be a nightmare and I may want to source brand new, pre-bent lines if it looks that terrible. I don't want to mess with a safety item such as brake lines and not knowing how well this guy knew how to flare lines.

Engine swap plan will be to run the stock Aztek PCM with only the 3800 engine values copied over. This way any other information being passed between modules and the PCM there won't be any unforeseen issues. I will use the engine harness from the donor vehicle and have to repin a couple wires to match the Aztek PCM.

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lonewolf04
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« Reply #5 on: April 02, 2019, 05:43:19 PM »

Well, a terrible update and a lesson learned. Since the exterior body was in such good shape I didn't get under the vehicle and inspect much, even after I had it on the trailer. Mainly because I was still sick as a dog and it was a long drive out there to get the Tek. It has some pretty severe rot on the rear door pockets. Pinch rail is shot and can tell someone lifted on it and ripped it up some too. All the brake lines the guy did were garbage, both fronts leaking at the flex hoses and the one rear I saw rubbing between the subframe and body. I didn't even want to look elsewhere. Rest of the unibody has a lot of surface rust that is hard to tell how bad it is. Pinch rails are mostly shot all on the vehicle. Front radiator support rotted out so the radiator is just hanging there. I don't even think at this point it is worth continuing with this vehicle unless there is a good way to cut out the pinch rail and maybe box in some new tube steel in place of it. Before working on anything mechanical I would want to drop the rear diff/suspension and fuel tank and scrub the thing clean and epoxy what I can that is good. I could see this thing taking over a year to get on the road. I am guessing this thing was parked in a lot with tall grass and all the moisture just ate away at it. Pretty sad actually. Well I have a couple months to think about either parting this thing out and scrapping the rest, or taking a huge plunge on trying to fix it.
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Pontiac6KSTEAWD
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« Reply #6 on: April 03, 2019, 09:25:17 AM »

Where do you live? I have some resources at finding vehicles, and I might be able to find something that might be in a better pre-mod shape.
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Brian - Carpe Diem

01 Pontiac Aztek GT OPT AWD 121k - 04 GMC Envoy XUV 182k - 05 Mercury Montego Premier AWD 52k (wrecked)

lonewolf04
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« Reply #7 on: April 03, 2019, 02:04:19 PM »

I live in Mid-Michigan. I know that part of the rear door opening structure is a spot susceptible to not just rust, but complete rot out when you start looking at used Teks. I will probably grab the air hammer this weekend and start banging away to see what is salvageable. Since I know eventually all Teks will fall to that cancer area. I might try do a support structure out of boxed 14ga steel running in place of the pinch weld length of the vehicle with some type of supports going to the floor pan to mimic what was done from the factory.

There is a black AWD Tek an hour from me that's got 158k miles, but wasn't wanting to spend $2k on it, though it could save me a lot of other unnecessary replacement items and cleaning. It could very well have the same issue, probably not as bad though.
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