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Author Topic: Topic: 2002 Suburban 2500 build thread, Part 4  (Read 52562 times)

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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #750 on: September 18, 2020, 03:08:22 PM »
Don, you sure that Aussie controller is spinning them in the right direction and not backwards?


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Yep, sure am
When they are on, you can REALLY feel it blowing aft over the engine.

Has me thinking if some fender side vents or hood louvers would give all that air some more ways to exit.
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Offline Bigdave_185

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #751 on: September 18, 2020, 11:37:53 PM »
Just take the hood off


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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #752 on: September 19, 2020, 10:30:05 AM »
Just take the hood off


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^^^^^You people see that right there!

Think we are witnessing symptoms of DS disease right here

"Dave Syndrome" Makes people who suffer the malady seem all backwards, and goofy! It is said that some people sufferin' the deadly disease appear to been born without a brane!

Ya, I know I misspell'd brain. May be sufferin' from DS a little bit meself...

Another symptom is running over expensive things that you own ;-)
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Offline Bigdave_185

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #753 on: September 19, 2020, 10:38:47 AM »
Iv got the truck to do it today.  Pull it up here and we will fix that over heating burb


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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #754 on: September 19, 2020, 08:55:44 PM »
Hopefully, all of you will see it in person in good time.

So today I rewired the fans again. Here is the bracket I made up to hold the maxi fuses. Just look at the size of those things and the thickness of the wire!
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #755 on: September 19, 2020, 08:56:44 PM »
They stack in tight on the mount
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #756 on: September 19, 2020, 08:58:02 PM »
All wired in
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #757 on: September 19, 2020, 08:59:20 PM »
Then I finally added the boost gage tube. I pulled the three-bar pressure sensor and added in a "T" to make it all fit
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #758 on: September 19, 2020, 09:04:17 PM »
All buttoned back up and even taped a spare fuse in there just in case.

I ran it for awhile with not so much as a hint of trouble. Fan one is on at 186F, then fan two ten seconds later. Both run until the temp reduces to 180 which takes about 20 seconds. Then the fans switch off and the temp continues to fall as low as 174, then the cycle repeats itself. I went through 4-5 evolutions with not so much as a hint of trouble. I may have this issue put to bed.

I now have to tuck the bottom of the wheel well and well liner in a little bit and pin it. The tires are catching the lower edge now with the larger diameter. With that (tomorrow hopefully) It will go off to get some more dyno time and that will more or less finish it until I get back to changing more things up.
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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #759 on: September 21, 2020, 07:53:24 PM »
Really just cleaning up the secondary punch-out list created by the new tires and fan fix. Today I fixed a new inner fender rub problem which mounting the 37" tires created

You can see the scrape marks, but what you can't see is how the tire actually grabbed the inner fender liner and pulled it forward onto the top of the tire going in a forward direction.
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #760 on: September 21, 2020, 07:54:36 PM »
Pulling out the plastic pins, the underside along with the ratty looking soundproofing is exposed
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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #761 on: September 21, 2020, 07:56:26 PM »
A relief cut is made to the inner piece of sheet metal and that is temporarily folded down. This allows clean access to the metal behind which must also be sectioned
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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #762 on: September 21, 2020, 07:58:19 PM »
Next two intersecting cuts are made to the innermost structure which will allow the outer metal which supports the fender liner to fit further aft than stock
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #763 on: September 21, 2020, 08:01:35 PM »
Next the sandwich section of the cowl and rocker structures is bent aft to a point perpendicular to the fore/aft axis of the vehicle. A hammer is necessary to move the steel. and although this may look fairly rough, it actually isn't. It's just that a bunch of paint is knocked off the metal during the hammering.

I liberally coated all surfaces with the Cosmoline cavity wax
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #764 on: September 21, 2020, 08:02:58 PM »
Finally, the lower piece of sheet metal is folded back up along the new contours creating about two inches more clearance
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #765 on: September 21, 2020, 08:04:16 PM »
A before and after comparison on the right wheel well shows the added clearance gained through this popular modification.
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Offline JR

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #766 on: September 21, 2020, 08:45:15 PM »
You removed the battery (post 756) for all the wiring? Those are massive fuses, hope that is the real issue.

Fender fix, did that years ago on mine, works good. I covered everything in undercoating.
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #767 on: September 22, 2020, 03:12:36 PM »
You removed the battery (post 756) for all the wiring? Those are massive fuses, hope that is the real issue.

Fender fix, did that years ago on mine, works good. I covered everything in undercoating.
Most of the battery stuff is gone, but the hot cable makes for a good place to connect for power so it remains, although well covered.
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Offline JR

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #768 on: September 22, 2020, 03:18:36 PM »
I may move both my batteries to the rear on the Sub. I have seen them under a panel above the rear driveline. I like that.
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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #769 on: December 03, 2020, 03:48:50 PM »
Latest update:

I was still experiencing an intermittent fan operational problem. So, I threw in the towel and took it over to Duane the electrical guru at the local Cadilliac store. He can find a grain of salt in a snow storm! Its uncanny how good he is with electrical issues. It's interesting to watch as he will have wiring schematics, illustrations all over along with his and GM's testing equipment.

He investigated the problem and narrowed it down to an ohm reading that was different on either side of a connector. He pulled the pins and found where insufficient tinning caused by a wire that was just a size or two too small was causing the connection to fail when it had a significant load, kind of like a fuse that blows, but then welds itself back together when the truck cools off. Duane replaced the wiring and the pins and resoldered and just like that the problems have ceased to be.

The truck was fully up with no real issues to speak of. I started driving it here and there, nervous of a possible failure in some traffic jam on a single lane on some bridge near here that mysteriously burned up a month ago, but none of that materialized. The truck just keeps running. I have been turning it into my daily driver ever since the oil leak developed on the D-Max, because I am too lazy at the moment to crawl all over it in the freezing cold.

The burb is really running well! Now that I am driving it more, it seems to be settling down. Do those generation computers learn? Anyway, the mileage is nothing to write anyone about, and it is a bit noisy, and going over 65 is something it does with protest, but aside from that, it starts every time. It is also comfortable to drive, has a really tight turning radius (Because I accidentally filed away the steering stops...or maybe it was intentional)  and has pretty good power. I am going to have it tuned again to change some transmission parameters which will make it even better and I just ordered a 30" long round dynomax super turbo muffler. I want some rumble, but not all that much, and a mo-quiterer ride. I think I may pick up some dyno-mat and cover the floor to get it even mo-quieterer.

All in all I am digging my "new" ride.
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Offline JR

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #770 on: December 03, 2020, 05:26:19 PM »
Like to hear more about the oil leak, saw the new tires too. I would really like to find a tuner for mine, just not happy with current tune.

You know you could always go up a tire size to help with RPM. I thought those 488 would be a little low.
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #771 on: December 03, 2020, 06:38:41 PM »
Like to hear more about the oil leak, saw the new tires too. I would really like to find a tuner for mine, just not happy with current tune.

You know you could always go up a tire size to help with RPM. I thought those 488 would be a little low.
I can't go above 37" JR. These are the largest thing which will reasonably fit without cutting and lifting and creating a clown truck. If anything I'd like to lower it 1-2".
Oil leak looks like it from this really hard to get to nipple/rubber hose on the side of the front cover. It's a bear to get to and I am not completely sure that is the source. It's just that its been freezing cold, and I have to start with cleaning (water) before repairing. That and I am just about 100% done with having to constantly fix things all the time.
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #772 on: December 04, 2020, 03:04:47 PM »
Took the burb off roading today. Started as a simple drive down the farm road, but I made things interesting. I was leading a tanker truck in to top off my fuel tanks and he kept getting stuck or was barely able to climb an uphill grade. The road is pretty muddy as we currently have two dozers and an excavator working the front 100 acres, clearing brush to make room for pasture. Also taking out unnecessary berms, small hills and just moving a lot of dirt.

Anyway, right away, I noticed the Burb was having zero problem with any of it. Next I noticed how smooth the thing was in the rough areas. I never knew this about the Suburban before. I had this big grin while I drove through mud holes over rocks, and even crossed some wet and slick cross slope. That burb made it all seem easy. I am genuinely surprised and impressed with how well the suspension and big tires work with the 4.88's and the torque curve of the motor. It is a dream to drive on semi wicked trails and I can see it being a great tow vehicle with the abundance of torque.

No pics...I didn't intend to make it a play day, just spending a bunch of money on red colored diesel fuel. Paid 2.08 a gallon and only spent a little over $760.
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #773 on: December 10, 2020, 07:02:59 PM »
Swapped out the Magnaflow muffler for a DynoMax unit

The DynoMax has a 3" "turbo muffler" design with 3" internal piping and is 30" long. It has considerably more volume than the magnaflow it replaces

The goal is to get a quieter cruise and just less overall noise output.
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #774 on: December 10, 2020, 07:04:59 PM »
I tucked it in pretty tight while only having to shorten the pipes at either end by a couple inches.

It sounds authoritative but idles more quietly than before
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #775 on: December 10, 2020, 07:06:48 PM »
And yes, the burb as been doing some mud time as you can see. It's been in mud with a slippery base of about 4" deep and trudges right along without an issue at all.
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Offline stlaser

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #776 on: December 10, 2020, 09:18:30 PM »
Why not dump the exhaust out the rear? Looks like that broken dogs hind leg shaped exit pipe is a little low for comfort?
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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #777 on: December 11, 2020, 10:28:17 AM »
Why not dump the exhaust out the rear? Looks like that broken dogs hind leg shaped exit pipe is a little low for comfort?
I don't think I have enough room to throw the exhaust over the axle because of the panhard bar and relocated shocks.

Broken dog hind leg is not all that low and actually moved upward a bit from where it has been.

That dog does have a bark though, and the warrant officer does not so much like it...
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Offline Bigdave_185

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #778 on: December 12, 2020, 11:08:31 AM »
Just gonna leave this here


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Offline JR

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #779 on: December 12, 2020, 12:56:50 PM »
All the guys needs is a helicopter beanie.
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Offline Bigdave_185

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #780 on: December 12, 2020, 01:21:18 PM »
HA!


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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #781 on: December 12, 2020, 08:29:30 PM »
Yea, but that DynoMax is a great unit. Happy to have installed it. I can now use a lot more throttle without waking up the neighborhood. Bottom line is that the Burb just got a bunch more powerful

and

The pre-Ranger loves the sound his truck now makes with the Magnaflow tucked up in his frame rails.
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Offline stlaser

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #782 on: December 12, 2020, 08:47:37 PM »
Bottom line is that the Burb just got a bunch more powerful.

Did I miss the coffee can exhaust tip install?  :huh:
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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #783 on: December 13, 2020, 07:49:33 AM »
So many people to fire...so little time - Don Harward


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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #784 on: December 13, 2020, 10:40:23 AM »
So many people to fire...so little time - Don Harward


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Tex, would you be up to the task?
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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #785 on: December 13, 2020, 03:25:43 PM »
So many people to fire...so little time - Don Harward


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I need to hire a managing executive to take care of em'

Tex, would you be up to the task?
How's a manager fire himself?
Conflict of interest if you ask me.
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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #786 on: December 28, 2020, 05:20:32 PM »
OK, back at it for the next round of modifications.

After driving it for awhile now, most everything is working except for some buzz in the stereo. I think I may have missed hooking a ground back up after the interior re-do, so I'll search after that tomorrow.

A persistent problem has been with highway cruising. Although it will cruise at 80 mph, the RPM is just too high, above 2500. Therefore I am making the switch down one notch to 4.56. I ordered the front gear and bearings from Tate, Randy's worldwide and for the rear axle I'm doing something pretty cool.

The D80 is huge, as in big and heavy, so I'm pulling it out for good. I contacted Shawn, Great Lakes Off Road to build me a proper 14 bolt silverado axle setup. Using Yukon gear stuff, he will add the new 4.56 gears to a Dura-Trac diff and do some mild reconditioning then ship it to me.

So why swap from a D80? Well several reasons. First the D80 is very heavy, and is sucking up a bunch of horsepower accelerating that mass which costs me fuel mileage and performance. Secondly, I have not had an emergency brake since I removed the problematic hydraulic shunt valve. I had four different lines on that setup and all of them leaked, so I pulled it and have been without the parking brake ever since. I will now get that back.

I'll let Shawn talk up the axle build details but that is all we have on that front at the minute.

Next the truck is going to go through another tune session. I have identified a bunch of little things that need to be adjusted to dial this thing in a little better.

I will be removing the roof tent since I am just not using it and have the camper to sleep in if needed, and it will reduce weight and get that weight off the roof.

All in all the suburban rides and operates very nicely, but these and another big change I have not mentioned will add to the drivability and fun factor a bunch more.
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Offline JR

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #787 on: December 28, 2020, 05:49:28 PM »
Heck about time. Bet you could have had two 14bt for the work in that monster!! I like my posi in back but kinda wish I had gone with the True-trac, just no cluches to worry about. Its almost to much sometimes, a little bias might be nice.

You will like the 4.56 better too. I turn 2k at 70 with the 35s, but I have double OD too.

I bet that camper causes more drag than the weight issue, but both will help.

Part what now.
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Offline stlaser

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #788 on: December 28, 2020, 06:32:09 PM »
Ok, so I’m sourcing Don a 99-10 AAM 14 bolt 10.5 full floater axle. I move a lot of these as they have oem disc brakes and a functioning emergency brake setup which is cable operated. We’re going to get a solid core unit in and strip it down to be sandblasted.

Then from our very own Tate @ Randy’s Ring & Pinion we’ll source some new internals. As stated it will be a Yukon dura trac carrier which should lend itself well into this vehicle and its capabilities. The 4.56 R&P with extended warranty’s on it and the carrier will be added because well it’s for Don. I think the why is self explanatory, enough said....

I’ll go thru all the bearings with new Timken units and add a Yukon crush sleeve eliminator to solve any future issues with Dons right foot and pinion preload, this also makes servicing the pinion seal in the future much easier.

Finally we’ll add a GLO HD cover, lube locker gasket and some GLO ujoint girdles for that 1410 yoke.

I’ll crate it up and send it Dons way. Pictures of build to follow shortly.
« Last Edit: December 28, 2020, 06:32:45 PM by stlaser »
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Offline TexasRedNeck

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #789 on: December 28, 2020, 08:08:44 PM »
Some alien abduction?  Don is starting to think more practically.....


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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #790 on: December 28, 2020, 09:01:43 PM »
Some alien abduction?  Don is starting to think more practically.....


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So the Dana 80, 4” axle tubes and 11.25” ring gear versus 14 bolt with 10.5” ring gear and 3.5” axle tubes. Down side of 80 imo is worse ground clearance and pinion bearings always seem to get wiped out, plus lack of extra pinion bearings support.

Tate, what’s your thoughts?
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Offline KensAuto

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #791 on: December 28, 2020, 11:05:27 PM »
I can't believe he's going to get any kind of warranty, especially an extended version!
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Offline Bigdave_185

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #792 on: December 28, 2020, 11:26:51 PM »
You gonna put that 80 in the 6.0 boys truck?


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Offline stlaser

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #793 on: December 28, 2020, 11:31:12 PM »
I can't believe he's going to get any kind of warranty, especially an extended version!

Ken, Tate sells a quality product and I stand behind my work so we feel confident in that warranty. Not sure how shops do it in Southern AZ but it doesn’t sound like you have much faith in your work? :popcorn:
Living in the remote north hoping Ken doesn’t bring H up here any time soon…..

Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #794 on: December 29, 2020, 10:48:06 AM »
You gonna put that 80 in the 6.0 boys truck?


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I'm gonna to put it up for sale!
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Offline KensAuto

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #795 on: December 29, 2020, 01:09:03 PM »
I can't believe he's going to get any kind of warranty, especially an extended version!

Ken, Tate sells a quality product and I stand behind my work so we feel confident in that warranty. Not sure how shops do it in Southern AZ but it doesn’t sound like you have much faith in your work? :popcorn:
Not that at all. Plenty of faith in Tate's products. I just have zero faith in your shipping ability, and Don's right foot!
;P
« Last Edit: December 29, 2020, 01:10:36 PM by KensAuto »
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Offline EL TATE

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #796 on: December 29, 2020, 01:33:38 PM »
OK, back at it for the next round of modifications.

After driving it for awhile now, most everything is working except for some buzz in the stereo. I think I may have missed hooking a ground back up after the interior re-do, so I'll search after that tomorrow.

A persistent problem has been with highway cruising. Although it will cruise at 80 mph, the RPM is just too high, above 2500. Therefore I am making the switch down one notch to 4.56. I ordered the front gear and bearings from Tate, Randy's worldwide and for the rear axle I'm doing something pretty cool.

The D80 is huge, as in big and heavy, so I'm pulling it out for good. I contacted Shawn, Great Lakes Off Road to build me a proper 14 bolt silverado axle setup. Using Yukon gear stuff, he will add the new 4.56 gears to a Dura-Trac diff and do some mild reconditioning then ship it to me.

So why swap from a D80? Well several reasons. First the D80 is very heavy, and is sucking up a bunch of horsepower accelerating that mass which costs me fuel mileage and performance. Secondly, I have not had an emergency brake since I removed the problematic hydraulic shunt valve. I had four different lines on that setup and all of them leaked, so I pulled it and have been without the parking brake ever since. I will now get that back.

I'll let Shawn talk up the axle build details but that is all we have on that front at the minute.

Next the truck is going to go through another tune session. I have identified a bunch of little things that need to be adjusted to dial this thing in a little better.

I will be removing the roof tent since I am just not using it and have the camper to sleep in if needed, and it will reduce weight and get that weight off the roof.

All in all the suburban rides and operates very nicely, but these and another big change I have not mentioned will add to the drivability and fun factor a bunch more.
***WAIT TO TUNE IT UNTIL AFTER THE RE-GEAR***
Husband, Father, Gear guy, Patriot.

Offline Sammconn

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #797 on: December 29, 2020, 02:37:41 PM »
^THIS!!!!
Or you’ll be redoing it again.
Insert definition of insanity here...
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
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Offline JR

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #798 on: December 29, 2020, 03:07:03 PM »
Bought time for another thread!
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Offline Flyin6

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Re: Topic: 2002 Suburban 2500 build thread, Part 4
« Reply #799 on: January 03, 2021, 05:35:01 PM »
So, a couple of things

First, I have the front gear and bearing kit from Tate at Randy's Worldwide.

I think Shawn has the rear axle purchase in the pipeline

And this: I have been thinking about getting into engine tuning with HP Tuner

I joined up at the web site and have been studying non stop. From what I have read, I can see a bunch of things to look at.

I can remove some of the torque converter lockup which I think Nick set at a super conservative 10% what that means in real-life operation is that the truck almost never slips into lockup in overdrive resulting in higher RPM all the time and that has a lot to do with the fuel consumption. Secondly it is acting up at idle when cold ever since the change of Throttle bodies. I can smooth that out
When you stand on it, the motor takes a long time to build power and I am thinking there is not enough throttle enrichment happening. From what I've read, this is the number one source of power in these trucks. The factory has virtually none and tuners add more based on what the wide band is telling them and gains of 50HP are well within grasp with this LS motor.

I can do so many things and be able to make adjustments whenever I like, so I am definitely considering throwing down the cash and start tuning. That and I want to tune my boys Vortec-Max and bolt in the big torque cam I didn't use when the supercharger got installed. So, for so many reasons, including being able to tune Duramax and other diesels, I think I am about to hit the order button.

And, I have been working on a surprise addition, well, two of them, for this truck...
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