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Author Topic: 2002 Suburban 2500 Build Thread, Part 1  (Read 56668 times)

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Offline Bear9350

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Re: 2002 Suburban 2500
« Reply #550 on: January 02, 2019, 05:40:58 PM »
I like that! Have you done any square bodies? EI, mid 80's like my burb?

I've got most of the GM line from 99-13 with a few models missing here and there.  That's about it though.  I'm sure I could expand the line-up more but at the present this selection keeps me busy enough.  I'm asked about the 90's body style often enough and would be glad to do it if somebody local asked and was willing to let me use there truck for a few days but so far that hasn't happened.  It should be easy enough to do as those older trucks don't have nearly as much going on with the front end.

I'm fairly impressed, bear took a butt ugly front end on that 2003 and made it look great! That alone would sell me on his designs! Bravo :beercheers:

Thanks.  I have a specific front bumper for every model.  I don't try and make one bumper fit multiple bodies and add filler pieces like some do.

Offline JR

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Re: 2002 Suburban 2500
« Reply #551 on: January 02, 2019, 05:57:46 PM »
So, sure many are thinking this.

Cost for a bumper kit shipped.

Cost for file to cut local or excuse for a table!
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #552 on: January 02, 2019, 06:53:11 PM »
Bear,
Your capability is noteworthy
I'll send you a PM and share some ideas
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #553 on: January 02, 2019, 06:57:41 PM »
I quickly attached the tailpipe to the muffler to see if I like any of this setup. I can't say I do very much. The tailpipe exit point is going to make me a "Taildragger" on high departure angle stuff, so I will likely readdress this.

But I started the thing up anyway and it was running really funky. Mind you, the aft two O2 sensors are not connected and the computer has not been recalibrated, so I'm sure that accounts for the wacky engine behavoit. I did, however get a sample of the sound. It's much louder than stock, like a muffled bark
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #554 on: January 02, 2019, 07:01:22 PM »
And that's all that setup will ever see, tomorrow starts the engine teardown. I have everything sitting in the shop now after receiving the camshaft from the brown truck guy today.

So as per everyone's recommendations I have a truck cam, optimized to make a bunch more torque and more horsepower as well. I expect to be adding over 100 with the new heads which yield a higher compression ratio, the bump stick, the headers and open exhaust and of course a tune by BlackBear Performance.

With that done, I slid the storage cabinet into the back and was pleasantly surprised with a perfect fit!
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #555 on: January 02, 2019, 07:04:02 PM »
With it in there, I am looking at cargo configurations. Lots of area right here:
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #556 on: January 02, 2019, 07:05:05 PM »
The lids open with no interference
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #557 on: January 02, 2019, 07:06:21 PM »
I like this Suburban, well, I like all of them really. Just by folding down one of the rear seats, I retain passenger carrying capability while opening a goodly area up for baggage
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #558 on: January 02, 2019, 07:08:40 PM »
Back to the storage locker, the drawer slides operate quite will. I melted paraffin wax into all mating surfaces, worked that awhile, then sprayed with some silicone. It slides quite well, but also will stay put needing a bit of a tug to get started. That alone will prevent unintentional opening
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #559 on: January 02, 2019, 07:09:30 PM »
And the small drawer fits those three Bosch utility boxes perfectly.
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #560 on: January 02, 2019, 07:10:46 PM »
Imagine lying on the mattress on top of the cabinet with the window of the hatch open. It all fell at about the right height
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #561 on: January 02, 2019, 07:12:01 PM »
I'll be doing something to these areas to store some things without intruding into "Living" space.
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Offline JR

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Re: 2002 Suburban 2500
« Reply #562 on: January 02, 2019, 08:30:32 PM »
I remember those areas on the side from my old 96, pretty much the same.

Very nice fit and work by the way. The pass side will have lots of AC stuff under there, the drivers not so much.

Think there is a factory cover for all that too.

Nice spot for a shotgun behind the rear seat,,,,,,,,,,,,,,,
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Offline KensAuto

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Re: 2002 Suburban 2500
« Reply #563 on: January 02, 2019, 08:43:10 PM »
That turned out really nice. Great job Boss!
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #564 on: January 02, 2019, 08:43:55 PM »
I remember those areas on the side from my old 96, pretty much the same.

Very nice fit and work by the way. The pass side will have lots of AC stuff under there, the drivers not so much.

Think there is a factory cover for all that too.

Nice spot for a shotgun behind the rear seat,,,,,,,,,,,,,,,
Yes! Good call bro!
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #565 on: January 02, 2019, 08:53:23 PM »
That turned out really nice. Great job Boss!
Thank ya sir

Yep, got lucky!
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Offline Mrwoody

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Re: 2002 Suburban 2500
« Reply #566 on: January 02, 2019, 10:53:48 PM »
Can’t believe you covered up the subwoofer!!

Offline cj7ox

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Re: 2002 Suburban 2500
« Reply #567 on: January 03, 2019, 07:52:20 AM »
I really like the box, Don! Question: how are the lids for the forward bins secured, when closed? Also, how is the entire assembly secured to the floor?

Just curious for how all that will stay put if (God forbid) you get in a rollover situation.
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Offline TexasRedNeck

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Re: 2002 Suburban 2500
« Reply #568 on: January 03, 2019, 08:05:52 AM »
Has he ever been on his lid?

Errr...wait. I recall a chapter in the book....


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Offline cj7ox

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Re: 2002 Suburban 2500
« Reply #569 on: January 03, 2019, 08:18:13 AM »
Has he ever been on his lid?

Errr...wait. I recall a chapter in the book....


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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #570 on: January 03, 2019, 10:48:08 AM »
Can’t believe you covered up the subwoofer!!
Not a sub woofer...

And it doesn't matter if you cover up a sub woofer

Post a demerit! ;-)
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #571 on: January 03, 2019, 10:50:17 AM »
I really like the box, Don! Question: how are the lids for the forward bins secured, when closed? Also, how is the entire assembly secured to the floor?

Just curious for how all that will stay put if (God forbid) you get in a rollover situation.
I haven't added them yet, but a simple turnbuckle system, two the the rear seat frames in the front, and two to the aft floor mounted tie down points...pilot simple, and not easily screwed up!
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Offline Nate

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Re: 2002 Suburban 2500
« Reply #572 on: January 03, 2019, 12:31:02 PM »
I know you went over as a civi contractor pilot, but did they make you go thru the roll over trainer?
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #573 on: January 03, 2019, 10:14:07 PM »
I know you went over as a civi contractor pilot, but did they make you go thru the roll over trainer?
Never even heard of it, Nate...
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #574 on: January 03, 2019, 10:17:47 PM »
So as of this morning, I purchased an AutoCal from Black Bear Performance. They already shipped it to me. There is a process that I will detail here on this thread about how their process works.

Basically, I get the handheld, plug it into my OBD2 port and download a copy of the software already in the truck. This will serve as the basis for Justin to build upon. I'll email that to them, and he will make the changes IAW my desires and the modifications I am doing. When I get that back, I'll load it into the Burb and go happily on my way.

So it begins
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #575 on: January 03, 2019, 10:20:01 PM »
And, I started the engine disassembly today. THings came apart quite easily

That fan came right off after smacking a punch against one of the flats of the nut. Makes me wonder if it had been off recently???
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #576 on: January 03, 2019, 10:21:32 PM »
Taking my time as I went along, things just kept coming right off fairly easily
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #577 on: January 03, 2019, 10:22:42 PM »
The harmonic balancer bolt, a 24mm biggin, broke my first socket, but I had a spare!
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #578 on: January 03, 2019, 10:23:50 PM »
Next I went after the coil packs and wiring harness.
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Re: 2002 Suburban 2500
« Reply #579 on: January 03, 2019, 10:25:51 PM »
At this point the crankcase and engine internals is more or less still sealed, and I wanted to keep it that way for a time. I sprayed the purple detergent on the accumulated greasy areas, and will pressure wash them again tomorrow, allow to dry some, then continue disassembly
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #580 on: January 03, 2019, 10:26:38 PM »
I'm taking lots of notes and bagging and labeling things to make reassembly go well
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Offline stlaser

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Re: 2002 Suburban 2500
« Reply #581 on: January 03, 2019, 11:24:54 PM »
I always bagged and labeled stuff, never made a list though. Probably not a bad idea right there!
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Re: 2002 Suburban 2500
« Reply #582 on: January 04, 2019, 09:02:18 AM »
You have a puller for that balancer D? Not like the old ones.
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #583 on: January 04, 2019, 09:48:40 AM »
You have a puller for that balancer D? Not like the old ones.
Ken, you're reading my mind

Was on my way over to O'Reilly's this AM to borrow one. Any particular one you recommend??
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #584 on: January 04, 2019, 09:50:18 AM »
I always bagged and labeled stuff, never made a list though. Probably not a bad idea right there!
You saying you agree with something I did?

Sayin' Don's pretty smart

and that Big D's one of the bestest mechanics you have ever seen

That you admire him to the moon and back

That what you're sayin'???

:-0
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #585 on: January 04, 2019, 10:06:03 AM »
I have one like this, but it's a two jaw...errrrrrrrr.....
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Offline JR

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Re: 2002 Suburban 2500
« Reply #586 on: January 04, 2019, 02:08:12 PM »
Hey, he even used a nut to protect the threads!

What HB don't you need a puller for?
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Offline wilsonphil

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Re: 2002 Suburban 2500
« Reply #587 on: January 04, 2019, 03:22:06 PM »
Hey, he even used a nut to protect the threads!

What HB don't you need a puller for?

Cummins 12V  not sure about the 24V
« Last Edit: January 04, 2019, 03:23:08 PM by wilsonphil »

Offline KensAuto

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Re: 2002 Suburban 2500
« Reply #588 on: January 04, 2019, 03:42:21 PM »
Quite a few JR, like most asians.
 I just meant that the new chevys (ls style) take a special puller. No holes in the balancer, and takes a long pin that bottoms out inside crank hole...or I suppose, like the guy rigged in that pic.

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Re: 2002 Suburban 2500
« Reply #589 on: January 04, 2019, 09:02:20 PM »
I picked up a puller from OReillys today, a borrowed one. I didn't get to the HB in the teardown, that's next, so not knowing at this point how all that will turn out

I can say, this is a bunch of work! And I am wondering exactly how I am supposed to get those outside rear cylinder head bolts back in. Going to be a bear. Lots of body work in the way of things in this year range of truck...
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Re: 2002 Suburban 2500
« Reply #590 on: January 04, 2019, 09:21:56 PM »
So first up, I pressure washed the motor and the chassis parts that I could not reach earlier. I'm starting to get a pretty clean base to work with
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Re: 2002 Suburban 2500
« Reply #591 on: January 04, 2019, 09:23:49 PM »
When I pulled the intake manifold, I started to discover the missing 16 years of exposure to the environment. Oak leaves!
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Re: 2002 Suburban 2500
« Reply #592 on: January 04, 2019, 09:25:51 PM »
No real corrosion to speak of, just grease and dirt. I was vacuuming and wiping it down as I went along trying to minimize FOD to something inside the motor
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Re: 2002 Suburban 2500
« Reply #593 on: January 04, 2019, 09:27:16 PM »
I bagged the bolts and small parts in a baggie with purple stuff cleaner sprayed in as well. By tomorrow those parts will be clean as a whistle
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Re: 2002 Suburban 2500
« Reply #594 on: January 04, 2019, 09:29:33 PM »
I pulled the valley cover to get a look at the top of the oiled area of the motor and have a peek at the knock sensors. One was OK, one was heavily corroded and will get replaced

The valley cover and everything else is currently soaking in the purple detergent losing some non-necessary grease calories!
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Re: 2002 Suburban 2500
« Reply #595 on: January 04, 2019, 09:30:59 PM »
The valve covers were dirtier on the outside than on the inside. Whatever oil the previous owner has been using certainly did a good job of keeping things clean!
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Re: 2002 Suburban 2500
« Reply #596 on: January 04, 2019, 09:32:26 PM »
Same-same here. I may just wipe the rockers down and reinstall
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Re: 2002 Suburban 2500
« Reply #597 on: January 04, 2019, 09:34:01 PM »
Valvetrain is looking great! The pushrods will not be reused. I am switching to chrome-molly units supplied with the new cam.
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Re: 2002 Suburban 2500
« Reply #598 on: January 04, 2019, 09:35:11 PM »
The bare "317" head. Darned thing is clean, clean, clean
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Re: 2002 Suburban 2500
« Reply #599 on: January 04, 2019, 09:36:25 PM »
Some more wrench bending and I was down to a shortblock
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