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Author Topic: 2002 Suburban 2500 Build Thread, Part 1  (Read 56590 times)

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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #700 on: January 09, 2019, 09:39:00 PM »
Yea, so, I'm going to have to drop the pan

The work was going along just fine until I started to try and put that bolt into the oil pickup tube. I tried so many different ways to get the bolt to thread through the collar with almost no room and not really able to see anything. I think I stayed on that one bolt from Roughly 1650 until I quit trying around 1930.

I just don't have any confidence that I can even get the pickup tube bolted up so along with the dire warnings from all of you smart folks, I'm going to do whatever I need to do to just pull the pan, bolt it all up, get the new gasket done and reinstalled correctly.

As for pulling the motor, its a bit more than just 12 bolts. I'd have to first bolt the wheels on, take it off jack stands, push it backward which means the garage door would be open, and that right there is a no go working in temps in the 20's, remove the hood, pull a very busy wiring harness and on and on. Easily a days work on either end, i.e. two more days tacked on.

So I'll take the 90% solution and rip the pan off. New gasket in the morning.

If I like this combo alot when I am done, I might just get away with a supercharger and call it done. I don't want to make a career over tearing it apart all the time and end up incomplete like SquareD

So right away, I pulled the radiator. I have the big 34" HD unit in this truck which is good. None larger made except for aftermarket. The fan shroud(s) will not be reused. I ordered a factory electric fan assembly to replace the mechanical stuff with.
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #701 on: January 09, 2019, 09:40:53 PM »
The cam came right out with room to spare.

I did find a non stock additional transmission cooler sandwiched between the condenser and radiator which was sitting exactly where it needed to sit to interfere with the cam removal, but like I said, I squeaked by
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #702 on: January 09, 2019, 09:41:26 PM »
New and old bumpsticks
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #703 on: January 09, 2019, 09:43:11 PM »
I have used this Lucas assembly lube before. Super sticky stuff. Get it on your hands and good luck! I coated the cam liberally and slid it in the block
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #704 on: January 09, 2019, 09:44:35 PM »
I'm using GM performance LS7 lifters and lifter trays. Stick the lifters into the guides (Flat on two sides for alignment) and slide them into the lifter bores
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #705 on: January 09, 2019, 09:45:08 PM »
All buttoned up with new bolts
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #706 on: January 09, 2019, 09:46:41 PM »
I purchased a new cam retainer from GM performance, installed the lock-tited bolts and torqued them into place
« Last Edit: January 09, 2019, 09:48:08 PM by Flyin6 »
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #707 on: January 09, 2019, 09:47:51 PM »
Then the cam gear, new chain and new hardware
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #708 on: January 09, 2019, 09:49:11 PM »
So that Ken would be pleased, here is the new GM oil pump pickup tube O-Ring
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #709 on: January 09, 2019, 09:52:39 PM »
I squirted some assembly lube into the dry GM performance oil pump, then after rotating it some, chased that with some fresh Mobil 1 and worked that back onto the crank snout

And that is when the wait-ah-minute bolt snagged me for the next almost 2.5 hours

After failing so many times, I threw in the towel and came inside, showered and cooked up some Crab cakes

Back at it in the morrow after cutting down a dangerous tree and sawing that critter up into boiler digestible pieces
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Offline JR

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Re: 2002 Suburban 2500
« Reply #710 on: January 10, 2019, 03:03:21 AM »
I believe the hood has a "work" position built in (Ken). Undo the front bolt on the hood, point straight up and then that bolt will hold it vertical.

Good idea on the pan. I may have cleaned the block before all the new parts though.
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #711 on: January 10, 2019, 10:33:25 AM »
Work position hugh?

Learn something new every day!

Off to cuttin' down a big ole dead Ash tree

Then back to the task at hand
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #712 on: January 11, 2019, 10:04:02 AM »
Working with Brian (Bear9___) can't recall his number sequence... Working with him on the F/R bumper design

There have been changes to this, but here is the very first rendition of the Front:

And looking to add a grill guard arrangement similar to this:
« Last Edit: January 11, 2019, 10:10:32 AM by Flyin6 »
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #713 on: January 11, 2019, 10:09:38 AM »
And working on the rear bumper tire carrier arrangement for the axle/pivot
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #714 on: January 11, 2019, 10:33:09 AM »
I'm wondering where I can get the springs re-arched??? without exorbitant shipping costs??

My brand new 4+1 silverado leaves are 64" and the Suburban has a 60" spring. With both springs having the axle centered, I would be moving the rear axle aft 2" by installing the silvy springs, and have to really look at the rear spring hanger.

All of that = Too much work. So rearch is the logical choice since the stockers are in great shape although have flattened some. Now, I do have 5,000 capacity airbags going in there, but I don't want the bags to carry the weight, just carry additional weight...
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Offline DOOLEY

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Re: 2002 Suburban 2500
« Reply #715 on: January 11, 2019, 02:00:36 PM »
TRITON SPRINGS IN WALTON

Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #716 on: January 11, 2019, 08:05:19 PM »
TRITON SPRINGS IN WALTON
No friggin way!

How did I miss that?!?
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Offline stlaser

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Re: 2002 Suburban 2500
« Reply #717 on: January 11, 2019, 08:13:27 PM »
TRITON SPRINGS IN WALTON
No friggin way!

How did I miss that?!?

Old? Failing eyesight? Early onset dimentia?  :tongue:
Living in the remote north hoping Ken doesn’t bring H up here any time soon…..

Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #718 on: January 11, 2019, 09:40:55 PM »
TRITON SPRINGS IN WALTON
No friggin way!

How did I miss that?!?

Old? Failing eyesight? Early onset dimentia?  :tongue:
Possibly...
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #719 on: January 12, 2019, 07:28:10 PM »
Well, couldn't get to the Burb, really, was outside splitting up ash logs. Man that is a workout!

But I did get the small rear seat ripped out. Looking at mounting a 55-65 quart refrigerated cooler in that spot and getting some stuff stored behind that while still maintaining seats for two peeps in the second row.
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #720 on: January 12, 2019, 08:06:10 PM »
Subject: Weight
I am being very weight conscious with this build, removing as much unnecessary stuff as is practical, and scrutinizing everything getting bolted back on.
I believe the stock burb weighs in at 5795 in 2500 dress with 37.5 gallons of fuel

Removed/Changed

Exhaust manifolds                                 Replaced with lightweight headers                 *Weight reduction
Exhaust system                                    Replaced with aftermarket system                  *Weight reduction
Front hitch                                                                                                              *Weight reduction of 35 lbs
Removed third row seat                         Not Replaced                                                *-100 pounds give or take
Removes second row seat                      To be replaced with a cooler of 37 lbs             * small weight reduction
EGR system removed                            Not replaced                                                 - 4 pounds
Removed factory running boards            To be replaced with electric folding steps         *small weight reduction
Added rear storage drawers                                                                                       + 50 lbs

Still to come
Remove rear bumper                            Replace with steel unit                                    + additional weight over stock
Remove rear tow hitch                          New hitch incorporated into bumper                 +/- weight trade off Net weight gain
Add tire carrier                                     Removed factory tire carrier                            + Net weight gain
Upsized tires                                                                                                             + Net weight gain
Remove front bumper/supports              Replace with steel bumper                              + 100 pounds
Install winch                                                                                                             + 60 lbs
Remove factory cooling fan/shroud         Replace with electric fans                                *Small weight reduction

I think It will be a struggle to keep it around 6,000 pounds
Then

Add:
3 pax                             +650
Rooftop tent                   +150
can of gas                      +35
2 cans of water               +90
Assorted camping gear    +100
Baggage                         +40
Food/stuff in frig              +25
Who knows what????????????

And I'm looking at a mission weight of 7,200-7,500

So the truck is rated at 8600 GWT so I am good there, so brakes should be effective, handling and so forth with the upgrades but fuel mileage will suffer. On a really good day these things can score 14 mpg, but that is not the norm. I'd say I may see a high of 13 on the highway as a best number and 11 more typical. Now throw in uran crawling and off roading and I think I should plan for around 10 mpg and no more.

The big unknown is the increase in efficiency from the cam and tune. I am adding almost a point in compression which will help fuel economy. And the cam will be making a bunch more torque by 2,000 RPM which may translate into some saved drops of gas. But on the flip side a lot of driving at 75 mph with a lifted truck with a boxy roof tent (Read parasitic drag) and I have killed anything I may have gained.

Just thinking out loud here...
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Offline TexasRedNeck

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Re: 2002 Suburban 2500
« Reply #721 on: January 12, 2019, 08:18:09 PM »
Dont know that the pre rangers want to sit right next to each other for long road trips.

Have you thought about putting captains chairs, or two more front seats in the back and have the cooler in the middle?
Kids today don't know how easy they have it. When I was young, I had to walk 9 feet through shag carpet to change the TV channel.

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Offline Bigdave_185

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Re: 2002 Suburban 2500
« Reply #722 on: January 12, 2019, 08:31:15 PM »
I think the captain chairs are way more comfortable.




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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #723 on: January 12, 2019, 08:44:47 PM »
For the upcoming trip, there are only me and the two boys going so seating is perfect.

In the future, maybe two captain chairs if there is still room for a cooler between the seats.

I plan n the cooler being a semi-permanent installation.

Believe it or not, getting that single seat out of there was not easy. It fought me all the way out of the door
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Offline Dfarm01

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Re: 2002 Suburban 2500
« Reply #724 on: January 12, 2019, 11:30:04 PM »
I'm curious to see how you fare economy wise. I think the best I've seen in mine was on a road trip to Idaho where I did a whole tanks worth on the highway and got 12mpg. Lol. That's on a 34" tire with stock gears and no tune though.

Offline JR

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Re: 2002 Suburban 2500
« Reply #725 on: January 13, 2019, 12:18:36 AM »
Are you getting a second battery for the fridge? That will draw all night. My little seat cooler killed my batteries in a day!

As for mileage, I had 285's on mine and got 16mpg driving 65mph like a baby. Hope the mods help with that.
3 maybe 4 can sleep inside if you must. Hvae you done the front seat mod for full reclining? 10 min job.

Go synthectic rope on the winch, good weight savings there. Plus you can always double up the line for pulling power with a good snatch rope/strap making up for the length. (Nate)
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Offline TexasRedNeck

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Re: 2002 Suburban 2500
« Reply #726 on: January 13, 2019, 08:02:58 AM »
https://youtu.be/kVidSOKwEJg

something like this.  The guy in the video put a second right side folding section which is nice because they'll fold flat.  Or you can put front seats in the back which will allow you to add seat heaters and make them power adjustable.

Very civilized

https://www.ebay.com/itm/Tahoe-Yukon-Sierra-Silverado-Suburban-Seats-Leather-TAN-2003-2004-2005-2006-522/153303734871?hash=item23b19d5a57:g:5bIAAOSwpppcFAFb:rk:23:pf:0

https://www.ebay.com/itm/Tahoe-Yukon-Sierra-Silverado-Suburban-Seats-Leather-SHALE-2003-2004-2005-2006/264127004437?fits=Year%3A2005&hash=item3d7f323f15:g:ynwAAOSwBMpcNlu9
« Last Edit: January 13, 2019, 08:15:37 AM by TexasRedNeck »
Kids today don't know how easy they have it. When I was young, I had to walk 9 feet through shag carpet to change the TV channel.

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Offline wilsonphil

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Re: 2002 Suburban 2500
« Reply #727 on: January 13, 2019, 11:41:52 AM »
From the trips I have done I use the Edgestar unit and had no problems, I second the second battery.  If you buy a good portable fridge then the power draw is very low and most have voltage shut off to prevent battery drain but always better safe than sorry.  You can always get one of the little portable battery packs that you can leave in the glove box for emergency, they work very well.

Your rig will be heavy just get used to that my RC (the one that got rolled) was 7K with nothing in it and 3/4 tank of fuel, if you figure once you get Tools, recovery equipment, camping equipment, spare tire(s), winch, spare water/fuel it adds up real fast.

One thing to pay attention too is tire weight, I heard so of you mention General tires why I never even considered them is they are normally 10-15 lbs heavier than any other comparable unit of the same size.  Tirerack.com is a real good resource to compare the specs for most of the name brand tires at least the one they carry   

Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #728 on: January 13, 2019, 11:51:20 AM »
I'm curious to see how you fare economy wise. I think the best I've seen in mine was on a road trip to Idaho where I did a whole tanks worth on the highway and got 12mpg. Lol. That's on a 34" tire with stock gears and no tune though.
That's encouraging! The timing is not there in a stock tune, although there is a goodly amount of torque there in a stocker at 2,000 RPM.
Compression is way good to increase efficiency and the cam timing is everything. 114 centerline 4 degrees advanced is all about bringing in power early and keeping it at a lower RPM.
Now, I'm interested in your choice of a 34" tire...

I am just not settled with going to only a 33" or 32.5" 285R75-16 size. I'd much rather go up to a 295 or a 305 (34"-35") tire to bet the axle a bit more up and away from rocks without going crazy and getting a TTT (too-tall truck)...
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Offline Bigdave_185

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Re: 2002 Suburban 2500
« Reply #729 on: January 13, 2019, 12:08:44 PM »
What type of mounting system does your roof top ten have? Are you going to be building a rack for the top of the superburban?
Can you build some sort of aerodynamics to the roof/tent/rack?

Fast search on EBay showed lots of captain chairs available for the burb but mostly newer models.   I know the front seats in the older style and up o the 2010 didn’t cross over but the center sections did.   

I have noted over the years the wider tire causes more weight.   I never have had a logical reason to run a 12.50 tire but I do.   I might suggest a more narrow tire for all the street driving this might see in the future.  And than might be worth a change after your long road trip.


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Offline stlaser

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Re: 2002 Suburban 2500
« Reply #730 on: January 13, 2019, 01:05:24 PM »
The wider tire will keep you out of semi truck grooves on the highway. Biggest complaint I have with wife’s 4Runner is the pizza cutters that come stock.....
Living in the remote north hoping Ken doesn’t bring H up here any time soon…..

Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #731 on: January 13, 2019, 01:08:20 PM »
What type of mounting system does your roof top ten have? Are you going to be building a rack for the top of the superburban?
Can you build some sort of aerodynamics to the roof/tent/rack?

Fast search on EBay showed lots of captain chairs available for the burb but mostly newer models.   I know the front seats in the older style and up o the 2010 didn’t cross over but the center sections did.   

I have noted over the years the wider tire causes more weight.   I never have had a logical reason to run a 12.50 tire but I do.   I might suggest a more narrow tire for all the street driving this might see in the future.  And than might be worth a change after your long road trip.


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Yea, you have me second guessing with the captain chair comments you and Tex made. But I don't physically need the extra seat for this upcoming trip and I do need the space for a cooler, so for now the cooler wins out.

Tire size: I am focusing on height all the while knowing wider tires cost one in added drag (Fuel). So my selections are really running in the 33/34 11.00 tire sizing, not 12.50's which look good but are really not necessary
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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #732 on: January 13, 2019, 01:14:13 PM »
Roof top tents clamp on the side rails. Now my suburban has aluminum beams running front to back, anchored in four places. Them alone would easily carry the weight, but I want more of a configurable system. Therefore I plan to layer two sections of extruded aluminum longitudinally and join them with some cross beams. I want to allow space for the tent, but capture the space ahead of that up toward the windshield for gear stowage. I may bolt on the pioneer gear and jack up there this time. Only thing I don't like about that is adding weight up high when working off camber situations. But I plan to add some weight to the belly as well, another fuel tank and a battery.

I'm not doing anything for aerodynamics, unless some forward facing roof mounted lights provide air straightenin'
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Offline Bigdave_185

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Re: 2002 Suburban 2500
« Reply #733 on: January 13, 2019, 02:37:53 PM »
Do you remember the older ski racks?  I remember they had a little fun on them similar to what the semi trucks have to direct airflow  but lights work as well


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Offline Bigdave_185

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Re: 2002 Suburban 2500
« Reply #734 on: January 13, 2019, 02:41:06 PM »


I guess the thought I had was a windshield similar angle on the front of the rack,  the tent top things we have running around here are boxy looking

That was my thought is all


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Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #735 on: January 13, 2019, 06:08:09 PM »
I've seen that

I don't think mine will be as clean looking. The basket in front of the tent will have camp chairs and a table strapped in. Nothing neat about any of that...
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Offline longball

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2002 Suburban 2500
« Reply #736 on: January 13, 2019, 06:49:51 PM »
I don’t know how you feel about changing wheels but with the smaller lift you’re talking about a 285/75/17 might be worth a look.

Prices in that size range are also not outrageous. I was happy with these Coopers in 285/70/17 on H2 wheels.
https://www.tirerack.com/tires/tires.jsp?tireMake=Cooper&tireModel=Discoverer+AT3+XLT&partnum=875SR7DAXLT&vehicleSearch=false&fromCompare1=yes



Come to think of it, I still have those 5 H2 wheels in my shed and nothing to mount them on.....

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« Last Edit: January 13, 2019, 07:01:25 PM by longball »

Offline Flyin6

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Re: 2002 Suburban 2500
« Reply #737 on: January 13, 2019, 07:01:51 PM »
I don’t know how you feel about changing wheels but with the smaller lift you’re talking about a 285/75/17 might be worth a look.

Prices in that size range are also not outrageous. I was happy with these Coopers in 285/70/17 on H2 wheels.
https://www.tirerack.com/tires/tires.jsp?tireMake=Cooper&tireModel=Discoverer+AT3+XLT&partnum=875SR7DAXLT&vehicleSearch=false&fromCompare1=yes




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I haven't decided on the whole lift/tire size thing yet. Those Coopers are AT's. I need something much more aggressive than those. My farm alone will challenge the best of tires...
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Offline longball

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Re: 2002 Suburban 2500
« Reply #738 on: January 13, 2019, 07:03:53 PM »
For some reason I thought I read you were going to a less aggressive tire for your trip. BFG mud terrains come in that size. https://m.tirerack.com/tires/tires.jsp?tireMake=BFGoodrich&tireModel=Mud-Terrain+T%2FA+KM2&partnum=875QR7KM2RWLV2&vehicleSearch=false&fromCompare1=yes


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Re: 2002 Suburban 2500
« Reply #739 on: January 13, 2019, 07:41:18 PM »
For some reason I thought I read you were going to a less aggressive tire for your trip. BFG mud terrains come in that size. https://m.tirerack.com/tires/tires.jsp?tireMake=BFGoodrich&tireModel=Mud-Terrain+T%2FA+KM2&partnum=875QR7KM2RWLV2&vehicleSearch=false&fromCompare1=yes


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Know em well...That's the tire I have on my D-Max truck
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Re: 2002 Suburban 2500
« Reply #740 on: January 13, 2019, 07:43:08 PM »
So, I'm finding enough stuff to do with the motor and the engine bay, that I threw in the towel and decided to yank the motor out of the engine bay. Started with unbolting the AC pump and bungeeing it out of the way
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Re: 2002 Suburban 2500
« Reply #741 on: January 13, 2019, 07:44:59 PM »
Then came the lower transmission to converter cover which required me to remove the front driveshaft.

Like I said earlier, the cam bone is connected to the rear axle bones somehow...We are seeing the evidence here!
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Re: 2002 Suburban 2500
« Reply #742 on: January 13, 2019, 07:46:03 PM »
I had to pull the starter to be able to remove the torque converter bolts which I did with reckless abandon
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Re: 2002 Suburban 2500
« Reply #743 on: January 13, 2019, 07:47:56 PM »
Good call on pulling motor
Living in the remote north hoping Ken doesn’t bring H up here any time soon…..

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Re: 2002 Suburban 2500
« Reply #744 on: January 13, 2019, 07:49:58 PM »
I removed the remaining six transmission to block bolts, along with the motor mount fasteners and the remaining wiring harness connections. All that is currently holding the block in place is gravity.

The engine crane is not in my garage and like I always say, if you own a John Deere tractor it is likely broken down. Mine is, again, and in the shop where it has been most of its life, where I can't use it to move a couple hundred pound engine crane so I can use that. But the good news is that I still get to make payments on the thing although it is seldom if ever used!
« Last Edit: January 13, 2019, 07:52:31 PM by Flyin6 »
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Re: 2002 Suburban 2500
« Reply #745 on: January 13, 2019, 07:50:39 PM »
Good call on pulling motor
I hope so!

That darned friend of yours, Ken keeps pushin' me! ;-))
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Re: 2002 Suburban 2500
« Reply #746 on: January 13, 2019, 07:52:10 PM »
And speakin' of the Ken, he goaded me into buying a new water pump. So I did. And covered it with some shiny clear paint that is specially designed to quickly yellow and peel off!
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Re: 2002 Suburban 2500
« Reply #747 on: January 13, 2019, 07:53:17 PM »
Have most of the parts prepped for reassembly and stackin' up!
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Re: 2002 Suburban 2500
« Reply #748 on: January 13, 2019, 07:54:17 PM »
Ran across this very worn bump stop. Seems the suspension has been riding on it quite a bit, wouldn't you say? The other side is worse!
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Re: 2002 Suburban 2500
« Reply #749 on: January 13, 2019, 07:54:43 PM »
And the list just keeps getting longer!
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