Author Topic: 2002 Suburban 2500 build thread, Part 2 (Read 58574 times)

Flyin6 · « **Reply #450 on:** February 23, 2019, 10:51:49 PM »

Starting on the lift kit install. Inventory of the boxes: Complete

Flyin6 · « **Reply #451 on:** February 23, 2019, 10:53:19 PM »

It took some finagling to get the keys to let go of the torsion bars

The bars have a left and a right part number which differs

Flyin6 · « **Reply #452 on:** February 23, 2019, 10:55:01 PM »

Since the suspension was already removed, I started at, like, page 5 in the instruction booklet.

First up for me was to remove the frame mounted front axle, forward mount

Flyin6 · « **Reply #453 on:** February 23, 2019, 10:56:07 PM »

BDS supplies a plate to weld over the end of what's left. I did so and the darned thing fit perfectly!

Flyin6 · « **Reply #454 on:** February 23, 2019, 10:57:04 PM »

Then I sawed the upper ear off of the 9.25" AAM front axle housing

Flyin6 · « **Reply #455 on:** February 23, 2019, 10:58:10 PM »

I bolted in the passenger side axle drop bracket, then cleaned up the mounting pockets for the new front crossmember

Flyin6 · « **Reply #456 on:** February 23, 2019, 10:59:09 PM »

And bolted that into place where it occupies the pockets where the LCA used to reside

Flyin6 · « **Reply #457 on:** February 23, 2019, 10:59:48 PM »

And because of all the ankle biters today, that is all I got done so far on the lift

Bigdave_185 · « **Reply #458 on:** February 23, 2019, 11:30:25 PM »

All this done on the floor. Your a able man I tell ya. I did on my back once these things. Never again

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stlaser · « **Reply #459 on:** February 24, 2019, 12:47:26 AM »

Quote from: Flyin6 on February 23, 2019, 10:59:48 PM

And because of all the ankle biters today, that is all I got done so far on the lift

Rats, I hate rats.....

TexasRedNeck · « **Reply #460 on:** February 24, 2019, 07:58:07 AM »

Don. I’ve been looking for those pocket pieces you cut off and the OEM crossmember.

Think they’ll fit my 2001 3/4Ton HD frame??

I’d be willing to make you a deal on them if they do

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Flyin6 · « **Reply #461 on:** February 24, 2019, 08:50:57 PM »

Quote from: TexasRedNeck on February 24, 2019, 07:58:07 AM

Don. I’ve been looking for those pocket pieces you cut off and the OEM crossmember.

Think they’ll fit my 2001 3/4Ton HD frame??

I’d be willing to make you a deal on them if they do

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Well, you can have them, no worries.

Flyin6 · « **Reply #462 on:** February 24, 2019, 08:53:47 PM »

Well, I got to this point on the aft crossmember. I was going to throw it on ahead of the front axle, but the instructions called for the mounting of the front axle before this, so, I threw in the towel and started on that.

BDS has reworked the front bump stop location. It will now sit horizontally

Flyin6 · « **Reply #463 on:** February 24, 2019, 08:55:28 PM »

I cleaned the thing a lot better before disassembling it

Flyin6 · « **Reply #464 on:** February 24, 2019, 08:58:08 PM »

There was some goop on the drain plug. It took a puller to yank off the front yoke

stlaser · « **Reply #465 on:** February 24, 2019, 08:58:34 PM »

Quote from: Flyin6 on February 24, 2019, 08:55:28 PM

I cleaned the thing a lot better before disassembling it

Uhm, is that a legit welding table?

Flyin6 · « **Reply #466 on:** February 24, 2019, 08:59:32 PM »

Quote from: stlaser on February 24, 2019, 08:58:34 PM

Quote from: Flyin6 on February 24, 2019, 08:55:28 PM
I cleaned the thing a lot better before disassembling it

Uhm, is that a legit welding table?

Sure is, masonite!

Flyin6 · « **Reply #467 on:** February 24, 2019, 09:00:52 PM »

I yanked off the stubby axle, then split the case. Pretty straight forward

stlaser · « **Reply #468 on:** February 24, 2019, 09:01:27 PM »

Quote from: Flyin6 on February 24, 2019, 08:59:32 PM

Quote from: stlaser on February 24, 2019, 08:58:34 PM
Quote from: Flyin6 on February 24, 2019, 08:55:28 PM
I cleaned the thing a lot better before disassembling it

Uhm, is that a legit welding table?
Sure is, masonite!

You have a real vise attached to a Masonite top?

Flyin6 · « **Reply #469 on:** February 24, 2019, 09:02:47 PM »

I was able to pop the stubby shaft right out with no problem. But inside the cases it looked nasty!

Flyin6 · « **Reply #470 on:** February 24, 2019, 09:03:36 PM »

Quote from: stlaser on February 24, 2019, 09:01:27 PM

Quote from: Flyin6 on February 24, 2019, 08:59:32 PM
Quote from: stlaser on February 24, 2019, 08:58:34 PM
Quote from: Flyin6 on February 24, 2019, 08:55:28 PM
I cleaned the thing a lot better before disassembling it

Uhm, is that a legit welding table?
Sure is, masonite!

You have a real vise attached to a Masonite top?

The masonite is only a cover over a thick lumber table. I change out the tops now and then.

Flyin6 · « **Reply #471 on:** February 24, 2019, 09:05:08 PM »

Tate supplied the Randy's parts. Here is a master overhaul kit he sent me. I will end up using most of this stuff.

Flyin6 · « **Reply #472 on:** February 24, 2019, 09:06:07 PM »

The last thing to do was to punch out the old races and remove the old seals

Flyin6 · « **Reply #473 on:** February 24, 2019, 09:08:11 PM »

And then the reassembly started with a through chemical cleaning. Chem-Tool solvents are my fav for this chore. Works great on greasy things , spiders and wasp nests...Especially wasp nests.

Flyin6 · « **Reply #474 on:** February 24, 2019, 09:10:10 PM »

I started with measuring the thickness of the factory shims, then created the same thickness out of a set of shims from the Yukon kit. Then I pressed the bearing onto the pinion gear

Flyin6 · « **Reply #475 on:** February 24, 2019, 09:11:13 PM »

I destroyed this bearing separator...Chinaman junk!

Flyin6 · « **Reply #476 on:** February 24, 2019, 09:13:24 PM »

Starting to go through some tools. Broke a 22mm and a 21mm socket. Grenaded a big flat tip screwdriver and the dog chewed up the spare. Same dog walked off with my 1/4" drive ratchet and my deep 10mm socket. I broke the handle off the drop light, broke the handle of my big ball peen, and can't find my 3/8" 12 pt socket

Flyin6 · « **Reply #477 on:** February 24, 2019, 09:15:14 PM »

I dropped in the front bearing, then tapped home a new seal, then fitted the pinion gear with the first of two crush sleeves

Flyin6 · « **Reply #478 on:** February 24, 2019, 09:18:04 PM »

I sort of shifted gears (get it...shifted gears?? ;-) and stopped assembly to clean and paint the various parts. I think I'd rather switch to a clean state then proceed with the actual fitting of the gears into the case. So the aluminum got treated to gray enamel, while the iron/steel got a coat or three of black epoxy.

Bigdave_185 · « **Reply #479 on:** February 24, 2019, 09:50:27 PM »

Never seen the inside of a front axle. Seems pretty straight forward so far. More assembly photos please

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TexasRedNeck · « **Reply #480 on:** February 24, 2019, 10:14:18 PM »

Don. I should mention I have the full set of factory shop manuals if you ever need to research something.

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JR · « **Reply #481 on:** February 24, 2019, 11:27:05 PM »

Made some goo progress and broke a few things? Guess since it is pressed on your are not going to make setup bearings?

Looking at your lift picture reminded me of why I went with the Cognito lift. Spacers were just 1/2" vs what looks like 1"+ you have there. Just a personal preference to keep it narrow.

Watched a couple setup vids, like to see you do it!

Flyin6 · « **Reply #482 on:** February 25, 2019, 09:22:48 AM »

Quote from: Bigdave_185 on February 24, 2019, 09:50:27 PM

Never seen the inside of a front axle. Seems pretty straight forward so far. More assembly photos please

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Wilco!

Flyin6 · « **Reply #483 on:** February 25, 2019, 09:23:19 AM »

Quote from: TexasRedNeck on February 24, 2019, 10:14:18 PM

Don. I should mention I have the full set of factory shop manuals if you ever need to research something.

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I'll take em' ;-)

Flyin6 · « **Reply #484 on:** February 25, 2019, 09:26:07 AM »

Quote from: JR on February 24, 2019, 11:27:05 PM

Made some goo progress and broke a few things? Guess since it is pressed on your are not going to make setup bearings?

Looking at your lift picture reminded me of why I went with the Cognito lift. Spacers were just 1/2" vs what looks like 1"+ you have there. Just a personal preference to keep it narrow.

Watched a couple setup vids, like to see you do it!

Yea, not a big fan of widening the stance. That's why no stupid offset on the wheels. I have roughly the same/same on the D-Max, so should work
I went this way because this kit tucks the torsion bars up into the belly ala' factory. Cleaner, and no "Wait-ah-minute" moments crawling over logs and rocks.

JR · « **Reply #485 on:** February 25, 2019, 11:14:02 AM »

Are those plastic spacers?

KensAuto · « **Reply #486 on:** February 25, 2019, 02:35:24 PM »

Just found out what I'm getting Don for his birthday. A big wheel barrow to carry,. uh... his jewels around with. I've never had the courage to rebuild one of those diffs, and I doubt that I ever will.

Nate · « **Reply #487 on:** February 25, 2019, 04:17:47 PM »

it looks as though you got really lucky with the driver side letting go?

EL TATE · « **Reply #488 on:** February 25, 2019, 05:50:09 PM »

Quote from: Nate on February 25, 2019, 04:17:47 PM

it looks as though you got really lucky with the driver side letting go?

x2! I was waiting for the 2200 text message about needing a case half, (good for nuthin' so and so grumble grumble grumble)

TexasRedNeck · « **Reply #489 on:** February 25, 2019, 06:31:56 PM »

Quote from: Flyin6 on February 25, 2019, 09:23:19 AM

Quote from: TexasRedNeck on February 24, 2019, 10:14:18 PM
Don. I should mention I have the full set of factory shop manuals if you ever need to research something.

Sent from my iPhone using Tapatalk
I'll take em' ;-)

Sorry sir, if I wasnt clear. I have them and would be happy to help you research stuff and make copies or photos. Until I get rid of mine, I plan to keep them, THEN they are all yours!

Flyin6 · « **Reply #490 on:** February 25, 2019, 09:30:53 PM »

Quote from: JR on February 25, 2019, 11:14:02 AM

Are those plastic spacers?

Yes, like same material as my glock

Flyin6 · « **Reply #491 on:** February 25, 2019, 09:31:47 PM »

Quote from: KensAuto on February 25, 2019, 02:35:24 PM

Just found out what I'm getting Don for his birthday. A big wheel barrow to carry,. uh... his jewels around with. I've never had the courage to rebuild one of those diffs, and I doubt that I ever will.

It's a little heavy to be sure

Flyin6 · « **Reply #492 on:** February 25, 2019, 09:33:03 PM »

Quote from: TexasRedNeck on February 25, 2019, 06:31:56 PM

Quote from: Flyin6 on February 25, 2019, 09:23:19 AM
Quote from: TexasRedNeck on February 24, 2019, 10:14:18 PM
Don. I should mention I have the full set of factory shop manuals if you ever need to research something.

Sent from my iPhone using Tapatalk
I'll take em' ;-)

Sorry sir, if I wasnt clear. I have them and would be happy to help you research stuff and make copies or photos. Until I get rid of mine, I plan to keep them, THEN they are all yours!

Deal. Meanwhile PM me an address and I'll send that stuff you wanted

Flyin6 · « **Reply #493 on:** February 25, 2019, 09:34:50 PM »

Caught the dog rolling in the muck in the neighbors pond. This was going to be the last memory of a viable breathing dog. Then I put the gun back down and got back to working on the Burb!

Flyin6 · « **Reply #494 on:** February 25, 2019, 09:37:21 PM »

Some closeups of the differential. Standard open thing, nothing special. I am pointing out the bolt that retains the cross pin for the spider gears. I never had to remove the pin or the spiders, as the stubby shaft just came out with one little tap

Flyin6 · « **Reply #495 on:** February 25, 2019, 09:47:25 PM »

BTW, the book that comes with the gearset from Randy's has a shim thickness recommendation to start with. THis diff requires .032" so that's what I put behind the bearing on the pinion gear.

The ring gear went on normally with one big exception. The bolts screw on backwards, as in left handed thread. So I had the diff in my vise and I was "Loosening it" with an uber crap ton of force. Then it loosened up and snapped off! W H A T!!!

So I's goes to the second one and apply the same crap ton of uber force to it and it snapped in half too! That's when I started wonderin' to myself "Could this be left hand thread bolts? So I's set my 1/2" impact wrench to tighten and as easy as a summer clam, they open right up and release........

I pressed the ring gear onto the differential, locktited the bolts and torqued to 103 ft/lbs

Flyin6 · « **Reply #496 on:** February 25, 2019, 09:50:31 PM »

Next I torqued the pinion yoke onto the gear with like a million gigatrons. The outer bearing does not just slip onto the shaft, but is almost a press fit. So the only way to get it seated is to crank that yoke down until everything seats.

After that I took up oil painting and started my latest masterpiece.

Flyin6 · « **Reply #497 on:** February 25, 2019, 09:54:11 PM »

And then the whole thing was slapped back together again. After turning the thing some in both directions, I had to take it all apart to check what happened gearside. First hit and I like it. Fact is it looks like the pinion is a tad too deep into the ring gear but I'm thinking acceptable. And considering just how difficult it would have been to pull that pinion gear, It is what it is. Besides this part will almost never turn anyway.

rpar86 · « **Reply #498 on:** February 25, 2019, 09:54:11 PM »

I see a can of KBS paint there. That’s good stuff.

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Flyin6 · « **Reply #499 on:** February 25, 2019, 09:57:01 PM »

Quote from: rpar86 on February 25, 2019, 09:54:11 PM

I see a can of KBS paint there. That’s good stuff.

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I've had some good luck with it, and some failures too. I plan to use it on the axle shafts and driveshaft. I want to try and get some good runs to provide a vibration due to imbalance... 8</