Author Topic: 2002 Suburban 2500 build thread, Part 3 (Read 69958 times)

Flyin6 · « **Reply #300 on:** April 10, 2019, 10:45:19 PM »

Just look at the size of the bolts holding that ring gear onto the carrier. That's a 15/16" head

Flyin6 · « **Reply #301 on:** April 10, 2019, 10:46:49 PM »

Next, I started scrubbing everything with degreaser and soaking it with purple cleaner. After some pressure washing it was getting to be pretty clean

Flyin6 · « **Reply #302 on:** April 10, 2019, 10:48:13 PM »

The brake backing plates were cleaned as well. They will need additional rust removal and paint before reusing, but I'll use the same 96,000 mile old brake shoes!

Flyin6 · « **Reply #303 on:** April 10, 2019, 10:49:23 PM »

Removing the bolts, I just dropped the carrier onto the floor from maybe 3" height and the ring gear fell right off

Flyin6 · « **Reply #304 on:** April 10, 2019, 10:50:50 PM »

And I checked one more time

8 pinion gear teeth, and 39 ring gear teeth

= 4.8750 4.88!

Flyin6 · « **Reply #305 on:** April 10, 2019, 10:53:08 PM »

The duragrip is Yukon Gear's limited Slip differential which I'll use this time instead of a full up locker. I don't think there was a grizzly available, only the much harsher detroit locker which would be out of character for a people carrier.

Flyin6 · « **Reply #306 on:** April 10, 2019, 10:54:39 PM »

I cleaned that all up, then applied some assembly lube to the ring gear mating flange, then bolted it all up

Flyin6 · « **Reply #307 on:** April 10, 2019, 10:57:40 PM »

I was kind of on a roll up to this point, the point where I made a mistake

I did not check the factory carrier as closely as I should have. I should have noticed that the shims Tate sent were much smaller than the large spacers that fit outside of the carrier bearing races. Had I known I could have stacked that amount of shim beneath the bearing prior to pressing on the new bearings, but I didn't and now have to pay the price.

Flyin6 · « **Reply #308 on:** April 10, 2019, 11:01:58 PM »

So when I dropped the completed carrier back into the case, it went in easily...Something wrong with that...

And I could slide the carrier from side to side a little bit. So where's the tight fitting operation that needs a case spreader?

Had I placed the shims onto the carrier, then pressed on the bearing, I would have been golden

When things didn't add up, I looked harder, then immediately discovered my bo-bo.

Using a bearing puller, I got to work pressing on the bearing backside which goobered up the factory shim pack something fierce.

No worries with all that, I only really needed to measure it and build up a new stack of shims from the new Tate supplied parts

JR · « **Reply #309 on:** April 10, 2019, 11:03:20 PM »

On the bumper. What about adding a brace to the rear adding mucho KIA pushing ability. Same stuff I have been thinking on mine.

Flyin6 · « **Reply #310 on:** April 10, 2019, 11:06:02 PM »

I did get a good measurement at .1520"

I was able to build up a stack that came in at .1530"

One thousandth off is GTG, but I was unable to pry off the new bearing from the new carrier.

If I tug on it, the roller cage is distorting, and will be destroyed. But the bearing seats right against the case with only two opposing slots to stick a puller into. When I pull the cage will get destroyed, but will provide the room to grab onto the small spots of bearing inside to allow me to pull it off.

Translation: I'll need to purchase another bearing.

JR · « **Reply #311 on:** April 10, 2019, 11:06:19 PM »

I thought on Danas the shims go on the outside of the race. You shim for X preload after finding backlash?

Flyin6 · « **Reply #312 on:** April 10, 2019, 11:07:09 PM »

Quote from: JR on April 10, 2019, 11:03:20 PM

On the bumper. What about adding a brace to the rear adding mucho KIA pushing ability. Same stuff I have been thinking on mine.

That other piece is a leg of the engine hoist, not part of the bumper

Flyin6 · « **Reply #313 on:** April 10, 2019, 11:08:59 PM »

Quote from: JR on April 10, 2019, 11:06:19 PM

I thought on Danas the shims go on the outside of the race. You shim for X preload after finding backlash?

Not in this axle. THe outside of the race spacer is like twice the diameter of the shims Tater supplied that are clearly marked "Dana 80"
And the factory carrier was shimmed inside of the bearing...

Flyin6 · « **Reply #314 on:** April 10, 2019, 11:10:37 PM »

Well, with useful daylight still burning, I got after painting the housing. Using that brushable KBS epoxy, I gave it a coat. Looks like a piece of glass!

Flyin6 · « **Reply #315 on:** April 10, 2019, 11:11:41 PM »

I'm hoping the supplied neutralizer will keep the paint alive for another use or two

Flyin6 · « **Reply #316 on:** April 10, 2019, 11:12:37 PM »

So that's the state of the build as of closing tonight. Back after it in the morn

Flyin6 · « **Reply #317 on:** April 10, 2019, 11:13:39 PM »

Grill on the roof is going to either get the LineX or the KBS black treatment...undecided at this point

Bigdave_185 · « **Reply #318 on:** April 11, 2019, 07:50:55 AM »

Quote from: Flyin6 on April 10, 2019, 11:13:39 PM

Grill on the roof is going to either get the LineX or the KBS black treatment...undecided at this point

Why would you paint your grill? That will smell terrible when ya cook on it

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stlaser · « **Reply #319 on:** April 11, 2019, 09:48:55 AM »

You know, Norm and I were just talking the other day about that fancy clam shell puller Tate sells...

EL TATE · « **Reply #320 on:** April 11, 2019, 10:15:50 AM »

Quote from: JR on April 10, 2019, 11:06:19 PM

I thought on Danas the shims go on the outside of the race. You shim for X preload after finding backlash?

The outboard "shims" are really just spacers, designed a narrower carrier some years back when races kept spinning and damaging the softer housing material. The spacers now take that abuse and really serve no adjustment purpose. All the backlash shim and preload are under the bearing as Don found out the hard way. Bummer sir, how can I help?

stlaser · « **Reply #321 on:** April 11, 2019, 10:20:31 AM »

Quote from: Bigdave_185 on April 11, 2019, 07:50:55 AM

Quote from: Flyin6 on April 10, 2019, 11:13:39 PM
Grill on the roof is going to either get the LineX or the KBS black treatment...undecided at this point
Why would you paint your grill? That will smell terrible when ya cook on it

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OldKooT · « **Reply #322 on:** April 11, 2019, 10:59:04 AM »

Set up bearings *cough

EL TATE · « **Reply #323 on:** April 11, 2019, 11:08:18 AM »

Quote from: OldKooT on April 11, 2019, 10:59:04 AM

Set up bearings *cough

probably should have thought about those. Or that bearing puller. I don't think I've been banned yet, maybe it's my turn

stlaser · « **Reply #324 on:** April 11, 2019, 11:34:08 AM »

Quote from: EL TATE on April 11, 2019, 11:08:18 AM

Quote from: OldKooT on April 11, 2019, 10:59:04 AM
Set up bearings *cough
probably should have thought about those. Or that bearing puller. I don't think I've been banned yet, maybe it's my turn

I second that you’re long overdue!

OldKooT · « **Reply #325 on:** April 11, 2019, 12:41:48 PM »

Don I am sure tate can set ya up with a clam shell puller and set up bearings to do that job the simple way. NEW TOOLS LoL

Flyin6 · « **Reply #326 on:** April 11, 2019, 09:47:13 PM »

OK, well, I purchased a new bearing. I destroyed the new-old one getting it back off.

This time I added the factory shim stack under the same bearing as was shimmed in the Dana factory carrier.

It was a booger to get in there. Like nearly impossible. I pounded on it with a rubber mallet for some time and finally it nested.

But while it was closing down closer to hitting home the backlash on the ring gear was going away quick. I sort of knew I had a bad setup but I torqued the caps down anyway just to take some measurements.

Well, that didn't help. with the caps loose I could rotate the thing but with zero backlash. When I tightened the caps it locked up. No way to turn it at all, so I am all the way back to starting out fresh.

And I'm not going to do that. Much like that automatic transmission dodge junk thing I messed with, when it didn't come together, I took it to the pros

I called Cincinnati Driveline, the folks who build my driveshafts. They also set up differentials. The minute I told them what had happened, they said, "I don't know why people like those Dana's so much, we hate them! Too darned hard to work on and the Gm 14 bolts are so easy."

They have a stand and all sorts of setup bearings and machines to get the thing setup properly. He did caveat that for the $300-$350 a setup normally costs and considering it is a Dana with older gears, they would take a run at it and could give me some backlash but getting it perfect is a crap shoot.

I am so regretting not buying a used 14 bolt! Would have been done and running by now. But it is what it is, I own it and I'll see it to its end, but for me, no more Dana axles...EVER. I'm sticking with the GM stuff for now on.

This could cause a problem. They have several axles in queue before me, and said it would be a struggle to get it done by the first week in May, so now I'm nervous as this will likely affect my start date. I really need to have some time driving it to iron out the bugs, and this rear axle thing may trip me up.

But, there is a lot of other things to get done, so I'll switch to them starting with the rear bumper tomorrow. Get that hung, then start on the modifications on the front bumper, then on to the secondary battery and electrical system. Hopefully, the axle will come in and I'll have everything ready to throw it in there and get going.

To that end, I spent the afternoon finishing the suspension parts I just built, and got them into paint before stopping

Here is that rear axle paint 24 hours later:

Flyin6 · « **Reply #327 on:** April 11, 2019, 09:49:00 PM »

That's some hard stuff! I was able to gouge it and deeply scratch it when rotating the axle in the rack, but normal scraping it with a tool has zero effect.

I snapped this pic just as I got the diff installed:

Flyin6 · « **Reply #328 on:** April 11, 2019, 09:50:53 PM »

Then I spent some time cleaning and derusting some more parts, then chemically cleaned them before brushing on more KBS epoxy

Flyin6 · « **Reply #329 on:** April 11, 2019, 09:52:21 PM »

I'm disappointed that I could not finish the diff setup today, but even though I may have lost that battle, the war is still in progress, and judging from the enormous change in that truck, I may be winning still.

stlaser · « **Reply #330 on:** April 11, 2019, 10:08:58 PM »

Don, if you want to run that axle to Ft Wayne I know the guy who sets up the rear rear ends at Dana for testing purposes.

Seth, can put that together with his eyes closed. Let me know if you need his number? He did all our race trucks.

He may or may not have once cut a custom set of gears for a rock jock 60 housing after hours at Dana too. Didn’t like the setup he was getting so he made gears to his own specs.....

Flyin6 · « **Reply #331 on:** April 11, 2019, 10:12:51 PM »

Quote from: stlaser on April 11, 2019, 10:08:58 PM

Don, if you want to run that axle to Ft Wayne I know the guy who sets up the rear rear ends at Dana for testing purposes.

Seth, can put that together with his eyes closed. Let me know if you need his number? He did all our race trucks.

Too far my friend

I'll take the bird in hand. take me 90 min to drive up, drop off and ditty-mau back home.

Or are we talking an overnight deal??Drive up, grab a hotel, load the next day and come home???

stlaser · « **Reply #332 on:** April 11, 2019, 10:14:52 PM »

Quote from: Flyin6 on April 11, 2019, 10:12:51 PM

Quote from: stlaser on April 11, 2019, 10:08:58 PM
Don, if you want to run that axle to Ft Wayne I know the guy who sets up the rear rear ends at Dana for testing purposes.

Seth, can put that together with his eyes closed. Let me know if you need his number? He did all our race trucks.
Too far my friend

I'll take the bird in hand. take me 90 min to drive up, drop off and ditty-mau back home.

Or are we talking an overnight deal??Drive up, grab a hotel, load the next day and come home???

Last I knew Seth worked third, worth a shot to call and see what his schedule is. May be able to run up in morning and have him do it then run home. He used to work out of his brothers garage but as of late when axles are in a truck he was using Branik motor sports shop with lift.

Flyin6 · « **Reply #333 on:** April 12, 2019, 08:21:59 AM »

Quote from: stlaser on April 11, 2019, 10:14:52 PM

Quote from: Flyin6 on April 11, 2019, 10:12:51 PM
Quote from: stlaser on April 11, 2019, 10:08:58 PM
Don, if you want to run that axle to Ft Wayne I know the guy who sets up the rear rear ends at Dana for testing purposes.

Seth, can put that together with his eyes closed. Let me know if you need his number? He did all our race trucks.
Too far my friend

I'll take the bird in hand. take me 90 min to drive up, drop off and ditty-mau back home.

Or are we talking an overnight deal??Drive up, grab a hotel, load the next day and come home???

Last I knew Seth worked third, worth a shot to call and see what his schedule is. May be able to run up in morning and have him do it then run home. He used to work out of his brothers garage but as of late when axles are in a truck he was using Branik motor sports shop with lift.

Yea, I looked at the distances involved, not just a simple drive over. That's quite the drive. Thanks anyway but I'll stay with current plan.

EL TATE · « **Reply #334 on:** April 12, 2019, 09:42:40 AM »

How far from Eastern, California, or Burlington, Wickliffe, Murray, or Louisville KY? How about Dayton, Columbus, Lucasville, Pataskala, E Palestine, Junction City, Harrison, Twinsburg, Dayton or Garfield Heights OH?

OldKooT · « **Reply #335 on:** April 12, 2019, 10:11:02 AM »

if you didn't move the pinion depth, all you should need is some set up bearings and shims and a hour. Dana axles aren't hard to work on if you have the correct tools. YT SB80 I think is yukons part #....

dave945 · « **Reply #336 on:** April 12, 2019, 01:50:19 PM »

Quote from: EL TATE on April 12, 2019, 09:42:40 AM

How far from Eastern, California, or Burlington, Wickliffe, Murray, or Louisville KY? How about Dayton, Columbus, Lucasville, Pataskala, E Palestine, Junction City, Harrison, Twinsburg, Dayton or Garfield Heights OH?

Burlington is just up the road probably 20 minutes from Don

Don, if you get in a real pinch, we can pull the 14 bolt from under the blazer and you can rebuild it and put disk brakes on it and use it til you get back and have time to work on the Franken-axle. Then I’ll stick it back under the blazer. :)

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Bob Smith · « **Reply #337 on:** April 12, 2019, 01:50:47 PM »

Don, I know you would never abuse that trailer hitch "but" why not put a good hitch on it just in case you accidently tried. Those round factory receivers are just junk and you already have it removed.

Bigdave_185 · « **Reply #338 on:** April 12, 2019, 02:32:24 PM »

Quote from: Bob/OlallaWa on April 12, 2019, 01:50:47 PM

Don, I know you would never abuse that trailer hitch "but" why not put a good hitch on it just in case you accidently tried. Those round factory receivers are just junk and you already have it removed.

https://www.curtmfg.com/part/14080

No more junk GM hitcth. I tried amazon but couldn’t find it

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Flyin6 · « **Reply #339 on:** April 12, 2019, 03:34:46 PM »

OK, for the axle people: I dropped the mutant axle off at Cincinnati Driveline, the go to place in this area for all things, well, driveline. They said they would try and get to it next week. I think they liked the fact that it was all cleaned up and pretty.

Towing People: Chevy tow hitch=No good??

Didn't realize that, well can't have that business, better go and get that Curt unit you goodins recommend, because like Bob aptly pointed out, Although I am not known to abuse things, the possibility exists!

Bigdave_185 · « **Reply #340 on:** April 12, 2019, 03:45:50 PM »

Quote from: Flyin6 on April 12, 2019, 03:34:46 PM

OK, for the axle people: I dropped the mutant axle off at Cincinnati Driveline, the go to place in this area for all things, well, driveline. They said they would try and get to it next week. I think they liked the fact that it was all cleaned up and pretty.

Towing People: Chevy tow hitch=No good??

Didn't realize that, well can't have that business, better go and get that Curt unit you goodins recommend, because like Bob aptly pointed out, Although I am not known to abuse things, the possibility exists!

I am sure the tow rating and so forth matches up, but knowing that nice easy me bent my factory GM hitch we had better get you in a upgrade model!

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Flyin6 · « **Reply #341 on:** April 12, 2019, 03:52:22 PM »

Quote from: Bigdave_185 on April 12, 2019, 03:45:50 PM

Quote from: Flyin6 on April 12, 2019, 03:34:46 PM
OK, for the axle people: I dropped the mutant axle off at Cincinnati Driveline, the go to place in this area for all things, well, driveline. They said they would try and get to it next week. I think they liked the fact that it was all cleaned up and pretty.

Towing People: Chevy tow hitch=No good??

Didn't realize that, well can't have that business, better go and get that Curt unit you goodins recommend, because like Bob aptly pointed out, Although I am not known to abuse things, the possibility exists!
I am sure the tow rating and so forth matches up, but knowing that nice easy me bent my factory GM hitch we had better get you in a upgrade model!

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Appreciate the advice!

Just ordered the Curt Class VI from Amazon

Be here Thursday

Bigdave_185 · « **Reply #342 on:** April 12, 2019, 05:37:18 PM »

I couldn’t get my amazon to pull up anything larger than class 3 for some reason, is your frame bolt pattern same as the trucks?

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Bear9350 · « **Reply #343 on:** April 12, 2019, 06:23:18 PM »

Quote from: Bigdave_185 on April 12, 2019, 05:37:18 PM

I couldn’t get my amazon to pull up anything larger than class 3 for some reason, is your frame bolt pattern same as the trucks?

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My research had told me the suburban and truck bumpers were the same. But Don just sent me an email saying the bumper wasn't bolting upright, and after looking at some of Don's pics closer I can definitely say they are not the same.

Flyin6 · « **Reply #344 on:** April 12, 2019, 08:06:48 PM »

OK, dropped off the axle like I mentioned earlier, I think, and drove over to the Line-X shop in Erlanger. They are pretty new but have a pretty nice operation going on already. The showroom is well laid out and also features other truck and overland products

Flyin6 · « **Reply #345 on:** April 12, 2019, 08:08:26 PM »

The business end of their shop is focused on a large spray booth that looks like it can swallow nearly any vehicle!

Flyin6 · « **Reply #346 on:** April 12, 2019, 08:16:47 PM »

The crew there were super nice, well informed about their business, and judging from the work they just did for me, very capable an d experienced as well. The two gentlemen standing behind the bumper did the work and honestly acted as though they enjoyed doing unique projects like this one.

Jimmy pictured, and Brian, who was out of the shop at the time run the place

I gravitate to businesses like this one. Young doers making it happen! That's one of the things that makes this nation great!

Contact them at:

Line-X of Northern Kentucky
3126 Dixie Highway, Bldg B
Erlanger, KY 41018
linexnky.com
859 360-6634
859 750-6556

Flyin6 · « **Reply #347 on:** April 12, 2019, 08:19:35 PM »

The bumper coating job was terrific, and was their premium treatment with an overspraying of UV fighting clear coating which also brightens up the finish.

So getting the bumper home, the fun began

There was an immediate misalignment issue pictured here

With the holes in the bumper and the ones in the frame aligned the fit was way off

Flyin6 · « **Reply #348 on:** April 12, 2019, 08:22:07 PM »

So I had my boys lift it up as far as they could get it, but some "L" shaped protrusion which actually had the mounting holes prevented a proper alignment.

At this point it was obvious that something was amiss. I was thinking that perhaps Brian had used the wrong frame/vehicle file because had the file been correct, it should have fit.

Flyin6 · « **Reply #349 on:** April 12, 2019, 08:25:41 PM »

Not only did the thing nor want to fit vertically, but laterally, the mounts are about 3" from where they need to be.

OK, mistakes are sometimes made and this was starting to feel like a lemon, but I decided to make some lemonade out of it. Brian had done a terrific job building the thing, and the Line-X was outstanding, and I need a bumper, and I just paid for this one, so I guess I'll just have to add some Kentucky engineering to get it where it needs to be.