2002 Suburban 2500 Build Thread, Part 1

[JR]

Maybe there's a quake coming Don?

Going contact the seller on that case? Should be something you can do with a long distance buy and a checkout before hand.

[EL TATE]

What model of x-case do you have?

dunno Nate
Has the auto 4WD feature, 2H, Neutral, 4H, and 4L

NP246G. I have case saver kits, but you should only NEED it if the rear case half is magnesium. if it's aluminum you're gtg

[JR]

Tate, can you get the yoke kit for the 263hd for the dmax?

[Flyin6]

Maybe there's a quake coming Don?

Going contact the seller on that case? Should be something you can do with a long distance buy and a checkout before hand.

Longshot JR

I bought it from Rob in Michigan who business is hunting the world over for finds like this, then reselling. He found this one in Oregon. But good idea, I'll reach out to him.

[Flyin6]

JR, thanks again!

I found the owner and talked to him

What a gentleman! And what a truck! He was able to tell me the history of it. He owned it since 2006 and only used it for long highway trips, never as a daily driver. I know the service record somewhat now, and what it needs. I was right when I suspected the manifold had been removed. He said the mani cracked and he replaced it himself. I thought the alternator looked newer-check! He had replaced it along with the AC compressor, the rear brakes and had the transmission serviced. He had difficulty removing the front calipers, so I'm going to address that (today??)

Oh and I have procured a set of "243" casting LS GM heads which are now headed my way. Its coming together!

[Flyin6]

Talking to Vinci cams...

[JR]

Power is good. I was looking at heads and they are pricey for the LS. Sounds like you got some standup sellers there.

Think I found an LS intake for my 5.3 swap in the elky, the tall intake is a problem and looks funky.

[Nate]

did he happen to say anything about the transfer case?

[Flyin6]

did he happen to say anything about the transfer case?

Sure did. It has never been touched...

[Flyin6]

Polished this heat shield up. Don't know why, just did.

[Flyin6]

Then got after the drivers side

I expected that side to be awful, but it was not. Not very hard at all, just busier with all the wire looms.

[Flyin6]

Then in a quick minute, that side was on the ground. It had also been removed once, showing a non stock gasket

[Flyin6]

Last moment of life without attachment

[Flyin6]

The fit without a hitch. Easy to install from below, plenty of room. Now both tubes are in, time to see what fits and what doesn't in the exhaust.

[Flyin6]

But since the prior owner told me he did not change the front brakes, I will. So in preparation for all that, I pressure washed the front suspension best I could to get ready. I did find some dirt built up behind the fender well liner, so I cleaned all that up. I'll apply undercoating to that area prior to reassembly just to be sure

[Flyin6]

And here it was when I went in to ruin supper. BTW that heater I installed in my garage is kickin' booty! I haven't had a chill one this winter!

[JR]

Looks great so far.

[TexasRedNeck]

Does it NEED front brakes?  My 2001 had 125,000 and brakes were close to 50%

[JR]

My LBZ has 160k and the brakes are fine.

[stlaser]

Tate, can you get the yoke kit for the 263hd for the dmax?

If he doesn’t have it I would call Jesse at high angle

[Bigdave_185]

More shiny parts like polished heat shields?  Are you going to put on that fancy exhaust tip next lol


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[dave945]

He was going to use that as a megaphone next time he has to scream at the sky.


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[JR]

Tate, can you get the yoke kit for the 263hd for the dmax?

If he doesn’t have it I would call Jesse at high angle

Looks like good stuff, but I bet he got burned out 

[stlaser]

Tate, can you get the yoke kit for the 263hd for the dmax?

If he doesn’t have it I would call Jesse at high angle

Looks like good stuff, but I bet he got burned out 

Heck, I hadn’t thought about that. Guess I’ll call tomorrow & check on him....

[KensAuto]

I'd leave the brakes alone.  Like others said,  those factory ones go forever.  The rear ones will usually go first on those.

[stlaser]

I'd leave the brakes alone.  Like others said,  those factory ones go forever.  The rear ones will usually go first on those.

From experience hauling H around? 

[EL TATE]

I've got 3 of those t cases remanned with the pump saver kits sitting over in the Florence warehouse if you wind up yarding that one. I don't have slip yoke eliminator kits, but I do have the stockers available.

[Flyin6]

Does it NEED front brakes?  My 2001 had 125,000 and brakes were close to 50%

They look to be around 50% or so. But the rotors were pretty scaly with rust, and I question the integrity of the caliper O rings and possible pitting behind the pistons.

I think for safety's sake, I may just change out the wearable items

[Flyin6]

More shiny parts like polished heat shields?  Are you going to put on that fancy exhaust tip next lol


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You secretly want it for your truck???  ;-)

[Flyin6]

I'd leave the brakes alone.  Like others said,  those factory ones go forever.  The rear ones will usually go first on those.

I can confirm that. The previous owner replaced the rear brakes already.

[Flyin6]

I've got 3 of those t cases remanned with the pump saver kits sitting over in the Florence warehouse if you wind up yarding that one. I don't have slip yoke eliminator kits, but I do have the stockers available.

I don't understand what I'm dealing with here. Have no knowledge of this T-Case rub issue. What am I look ing for to access?

Do all of them eventually fail?

At about which point?

Previous owner stated that almost all of the miles on this truck were long drive highway miles, would that affect T-Case were of this nature one way or the other?

[rpar86]

I think the answer, Don, is "it depends".  I've heard of trucks never having an issue with "pump rub", and some failing sub 100K miles.

To remedy the situation, you have to drop and split the case, then replace the oil pump inside. Let me dig up some pics from when I did mine and get them attached here... maybe I'll start a thread.

[longball]

I think every truck is different. A buddy’s case failed at 50k miles. When I put the kit in mine at 145k miles it was just starting to show signs of wear. I caught it just in time.


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[EL TATE]

Sam did a write up on his I think... the pump has tabs that slide back and forth against the magnesium and wear tiny pinholes that slowly drain the fluid while underway, so you never really notice till it's too late. The actual cause of complete catastrophic failure on my truck and the reason I have a new Malibu...

[rpar86]

Speaking of Tate... any update on the Tahoe?


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[Sammconn]

It’s not that hard to do.
I was late but on time. Had a pinhole didn’t lose the case.
Whatever stuff I put on is still holding too.

Get the kit and do it before it’s too late.
I’ll look if my pics are still good.

[Flyin6]

I think the answer, Don, is "it depends".  I've heard of trucks never having an issue with "pump rub", and some failing sub 100K miles.

To remedy the situation, you have to drop and split the case, then replace the oil pump inside. Let me dig up some pics from when I did mine and get them attached here... maybe I'll start a thread.

This sounds painful!

[Flyin6]

Well, it sounds like I can dovetail into something else

I'm corresponding with Joe of Vinci cams. He is going to build the camshaft for my motor. He asked today if I was replacing the torque converter or leaving it stock.

Since I need to pull the transfer to fix this d)(#%! wobblin' pump part, I'd be half way there to the converter swap out...hmmm...

[Flyin6]

So, here's the rest of the Speed Engineering exhaust, the Y-Pipe

[Flyin6]

And of course this inquisitive little guy was all in my business. Named Trooper, I call him "Bub."

[Flyin6]

Bernese mountain mutt ^^^^^^^

(Bern Switzerland)

[Flyin6]

And here it is going in

I have to say, those narrow clamps are junk, pure junk!

I'll replace them with the good stainless wide band clamps

Oh and BTW, I did order the spark plug heat boots so you all will quit squawking!

[Flyin6]

It all ends here and here is where I had to start getting creative

[Flyin6]

So starting with the factory flange I cut it to size, then opened it up

[TexasRedNeck]

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[Flyin6]

Using that flange and a combination of new and old 4" tube, I started running the system aft

[Flyin6]

Using these parts, I created the stub, which I welded to another curved section of pipe to run past a crossmember to the muffler

[Flyin6]

I decided to make that whole run one piece, and weld on a hanger to start supporting the weight

[Flyin6]

Now the muffler ends about 14"-16" from where that massive tailpipe begins. So considering I only have a straight through 4" muffler to quiet things, I actually have the room to add a second muffler!

Remember that little one I took off of C-Max when I added the larger quieter one??? Well it just might see action once again.

I cut it down to get it as short as possible. With it slid all the way into the front muffler, the tailpipe is a few inches too long, so next up I may have to cut the front of it shorter to fit. But If I can swing it, I'll have two inline MBRP style mufflers which just may do a satisfactory job of controlling the noise.

[Flyin6]

That tail pipe is absolutely massive!