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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #850 on: March 14, 2019, 08:07:54 PM »
Then the stack was reassembled and the snap ring slid home to complete the stackup
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #851 on: March 14, 2019, 08:09:13 PM »
And placed the heavy half of the gearbox into a fixture so i could paint that half as well. I will reassemble the halves tomorrow
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #852 on: March 14, 2019, 08:14:27 PM »
I'll install new output seals, both ends before reinstalling it, but when everything is dry in the morning it will be time to silicone the case halves back together.

I got after the exhaust system. pulling it all off once more to get ready for the final installation of the muffla' story. Plus it makes it much easier to get in there.

When the case is bolted up, I'll be able to reinstall the transmission cross menber and the front drive shaft. That is going to get me way down the road on this massive project.

Before it moves under its own power, I will have touched literally everything that moves, rotates, slides, spins, pumps, or any other movement.

Think you can call me on not touching the fuel pump? Not so fast...Truck is going to get a Walbro
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #853 on: March 14, 2019, 08:15:09 PM »
And a new one of these:
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #854 on: March 14, 2019, 08:16:25 PM »
This will go Bye-Bye...No more hot pipe over the axle for me.

Have a little surprise in store for the void just behind the axle...Stay tuned.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #855 on: March 14, 2019, 08:19:18 PM »
Oh, and one of the gentlemen who purchased a bunch of SquareD parts made this up for me, so I gave it a home:

Square D is really gone. Sold the frame two days ago. All that is left is a hood, two fenders, a wiring harness, snorkel and a bunch of bolts. Everything else has found a new home on other old 1st Gens out there. The frame went to a Marine who when pulling the gas tank out of his truck, discovered his frame was almost rusted in half. It will serve well under its new command!
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Online Bigdave_185

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #856 on: March 14, 2019, 10:12:12 PM »
You going to order a dash mat? An overhead gun rack?  I have always liked the once that relocate your visors but never had the guts to tear into a headliner


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Offline JR

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #857 on: March 14, 2019, 10:14:03 PM »
Lots done again.

Sounds like SD came out OK. Glad you got a lot back out of it for what you put in.

I have to do the same pump work to mine still, mine leaked. BTW the pump works all the time, not just 4x4.

If this area here was a little wider (same as the 265?), we could run a 1350 vs a 1310 front universal.
 
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Offline KensAuto

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #858 on: March 15, 2019, 12:06:41 AM »
I know it's a little late but I use the same coolers on Cummins tranny's per trans builders advise. They work well.
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Offline JR

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #859 on: March 15, 2019, 12:16:49 AM »
I know it's a little late but I use the same coolers on Cummins tranny's per trans builders advise. They work well.

Aren't those exchangers not coolers? (same purpose) Ken, I was so wanting to call last night when the camry was giving me cooling issues, but it was late.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #860 on: March 15, 2019, 09:20:56 AM »
You going to order a dash mat? An overhead gun rack?  I have always liked the once that relocate your visors but never had the guts to tear into a headliner


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Dash mat? Elaborate?
Needed in the sunnier climes??
Overhead gun rack?? No knowledge>>>
Relocated visors? Why?
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Offline KensAuto

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #861 on: March 15, 2019, 12:09:13 PM »
Heat exchanger/cooler same same, no?
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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #862 on: March 15, 2019, 01:51:19 PM »
You going to order a dash mat? An overhead gun rack?  I have always liked the once that relocate your visors but never had the guts to tear into a headliner


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Dash mat? Elaborate?
Needed in the sunnier climes??
Overhead gun rack?? No knowledge>>>
Relocated visors? Why?
For extra do-dads and things
https://www.carid.com/vdp/shelf-it-black-overhead-storage-mpn-sh2167.html

To Keep glare of the window, reduces the haze buildup on windshields
https://www.covercraft.com/us/en/product/dashmat-custom-dash-cover.DMC




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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #863 on: March 15, 2019, 10:38:19 PM »
You going to order a dash mat? An overhead gun rack?  I have always liked the once that relocate your visors but never had the guts to tear into a headliner


Sent from my iPhone using Tapatalk
Dash mat? Elaborate?
Needed in the sunnier climes??
Overhead gun rack?? No knowledge>>>
Relocated visors? Why?
For extra do-dads and things
https://www.carid.com/vdp/shelf-it-black-overhead-storage-mpn-sh2167.html

To Keep glare of the window, reduces the haze buildup on windshields
https://www.covercraft.com/us/en/product/dashmat-custom-dash-cover.DMC




Sent from my iPhone using Tapatalk
Thanks!
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #864 on: March 18, 2019, 09:56:39 PM »
Feedback: Overhead console not sold for that year Chevy, at least I couldn't find it...

So tonight I plugged away at the transfer case. First installing some new seals
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #865 on: March 18, 2019, 10:00:44 PM »
I like the way these case halves turned out. THat KBS paint is super, super hard. Try to scrape a drip off the underside of the case, on the flange and it takes some serious omph to get it removed.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #866 on: March 18, 2019, 10:01:52 PM »
Buttoned up and ready to reinstall
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #867 on: March 18, 2019, 10:04:23 PM »
Reinstalled
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #868 on: March 18, 2019, 10:12:27 PM »
Front driveshaft and new trans mount in, ran out of time, but only lacking the crossmember to put this one in the bag.
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Offline TexasRedNeck

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #869 on: March 19, 2019, 06:56:56 AM »
Not sure what you mean that an overhead console not sold?

My 01 2500hd has an overhead console and I even took the home link garage door opener insert from a same year suburban to put in it since the trucks didn’t come with built in remote , only a compartment that held a big garage door remote and a door that had a button on it that aligned with the remote button inside so that when pressed it actuated the garage door remote.


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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #870 on: March 19, 2019, 08:21:45 AM »
Charles, thinking he was referencing the aftermarket unit Dave had mentioned earlier.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #871 on: March 19, 2019, 10:21:46 AM »
Charles, thinking he was referencing the aftermarket unit Dave had mentioned earlier.
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aDve's klni hswoed a looc aterfmraekt yrat, ubt ym gneaterino fo buSurnab swa tno cvodere

s'evaD knil dewohs a looc tekramretfa yart tub ym noitareneg fo nabrubuS saw ton derevoc

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« Last Edit: March 19, 2019, 10:34:06 AM by Flyin6 »
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Offline Nate

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #872 on: March 19, 2019, 10:32:43 AM »
HAHAHAHAHAHAHAHAHAHAHA
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #873 on: March 19, 2019, 10:38:24 AM »
So, I also ordered the entire roof rack structure yestertag.

This time I am going to use a simple bolt together extruded aluminum product called 80/20 aluminum extrusions.

I will bolt the side rails directly to and through the existing factory rack both anchoring and strengthening that system, and extending the rack into a rectangle from the rear ro almost the windshield.

The included slots will provide infinite possibilities for attaching things like the tent, a basket, lights, the kitchen sink and a milk jug just to get me started.

Seen the back to the future Delorean?? That's the look I am going for with Ravin8 :shocked:
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #874 on: March 19, 2019, 10:41:01 AM »
Oh, and the winch never arrived. I called to trace it down and found a shipping label had been created, but no further action was ever done. So, they are sending out another one and that should be here Friday ahead of the bumpers

It's coming together nicely!
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Offline wilsonphil

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #875 on: March 19, 2019, 08:56:34 PM »
So, I also ordered the entire roof rack structure yestertag.

This time I am going to use a simple bolt together extruded aluminum product called 80/20 aluminum extrusions.

I will bolt the side rails directly to and through the existing factory rack both anchoring and strengthening that system, and extending the rack into a rectangle from the rear ro almost the windshield.

The included slots will provide infinite possibilities for attaching things like the tent, a basket, lights, the kitchen sink and a milk jug just to get me started.

Seen the back to the future Delorean?? That's the look I am going for with Ravin8 :shocked:

Hey don if you are going the 80/20 route before you buy a bunch of stuff let me know I have tons left over from a few projects, it all depends on the size you are going to use

Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #876 on: March 19, 2019, 10:46:55 PM »
So, I also ordered the entire roof rack structure yestertag.

This time I am going to use a simple bolt together extruded aluminum product called 80/20 aluminum extrusions.

I will bolt the side rails directly to and through the existing factory rack both anchoring and strengthening that system, and extending the rack into a rectangle from the rear ro almost the windshield.

The included slots will provide infinite possibilities for attaching things like the tent, a basket, lights, the kitchen sink and a milk jug just to get me started.

Seen the back to the future Delorean?? That's the look I am going for with Ravin8 :shocked:

Hey don if you are going the 80/20 route before you buy a bunch of stuff let me know I have tons left over from a few projects, it all depends on the size you are going to use
Now ya tell me!

I am working the T-10 size 1" X 1" and 1" X 2"

Two side rails of the 2" stuff, 114" long, the front and back in 2", then 6 lateral bars evenly spaced along the length.

I will be using a combination of internal 90 degree and external 90's to assemble and add rigidity to it. From what I see, it should be as stout as a a WW2 battleship but super light.

I also have plastic filler strip to close in wiring that will extend to the various lights I mount up there, and some decorative end caps to make it look professional. Intermediate braces are 46.25" in length and all the tubing and hardware is black.

I could use some for the interior. Would like to assemble a catch-all rack and some other things.
« Last Edit: March 19, 2019, 10:47:53 PM by Flyin6 »
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #877 on: March 19, 2019, 10:49:38 PM »
So, here are the finish shots of the transfer case. Now that completes the engine, transmission, and transfer case, where everything got touched, rebuilt, replaced, renewed, or something. It's in like new condition
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #878 on: March 19, 2019, 10:50:47 PM »
And, yes, Tex, I remembered to fill the case with new fluid!
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #879 on: March 19, 2019, 10:52:48 PM »
There is an ordering to things. I would have assembled the exhaust, but without knowing where the exhaust sits and the relationship between that space and the room needed for step extension/retraction, I had to install the Amp Research steps first
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #880 on: March 19, 2019, 10:55:23 PM »
These three pics would suggest that I just threw the steps on there with little to no fuss, but that is no where near the truth.

The placement of those hinges requires some painstaking locating and drilling of holes, then an alignment process to make things come out OK. I was very pleased to be rewarded with a perfect fit of everything.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #881 on: March 19, 2019, 10:56:01 PM »
So far, so good
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #882 on: March 19, 2019, 10:57:05 PM »
Then I located the control module according to the instructions, then started to lay out the wiring harness
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #883 on: March 19, 2019, 10:59:10 PM »
I got some of that hooked up, but most of it remains to be completed. I also lengthened the transfer case breather. It used to vent right on top of the transmission. Now it has found a new home up near the hood line in the engine compartment.

I want to check the trans vent to ensure it, too, can stay high and dry.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #884 on: March 22, 2019, 10:44:23 PM »
After looking at the wheels that I had painted the centers black, I decided to remove the paint and either leave the finish alone as manufactured or acid etch them and paint them the massey gray I have been using lately...Jury is still out on that.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #885 on: March 22, 2019, 10:45:10 PM »
Brown truck brought the new winch. It's a heavy one!
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #886 on: March 22, 2019, 10:46:43 PM »
I told myself I would not stop until the Amp Research steps were completed, so I ran the left and right wiring harness and pulled the sill plates to make the connections inside the cabin
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #887 on: March 22, 2019, 10:49:41 PM »
But, the required diodes were not included in the parts, something Amp does intentionally. They require you to call them to order the diode and mini harness to complete the wiring. Therefore I could not finish the project tonight!

I did wire in and mount all four LED illumination lamps and secure the wiring harnesses

That was all I could complete and am left with maybe an hour's work making four wiring connections
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #888 on: March 22, 2019, 10:50:50 PM »
I could see about where the steps will stow, so it was time to finish the exhaust system

First in was the Y-Pipe, again.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #889 on: March 22, 2019, 10:52:02 PM »
Then, using a stack of 3" tubing bends, I started at the Y-Pipe outlet and worked my way backward, one painstaking piece after another
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #890 on: March 22, 2019, 10:53:08 PM »
By creating this "Misalignment" section, I got the muffler centered and tucked up into the chassis very neatly
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #891 on: March 22, 2019, 10:54:04 PM »
There is a lit of fitting and experimentation, but little bit by little bit, the system grew rearward
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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #892 on: March 22, 2019, 10:56:59 PM »
The actual tailpipe is a regular piece of spaghetti. The muffler outlet is several inches above the bottom of the frame rail. Therefore the pipe needs to turn downward, then, rotate aft and turn up again, hugging the lower countours, then angle aft and finally turn downward once again. Somehow I made all of that happen. After some finish welding and the creation of the hangers, this thing will be done too!
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #893 on: March 22, 2019, 10:58:04 PM »
And that's a good thing, because I picked up the frankenstein rear axle and am about to get started on it
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #894 on: March 22, 2019, 10:59:31 PM »
^^^^^^^^^ Dana 80 with 4.88 gears and 14 bolt Gm axle tubes, axles and ends.

This one is going to be interesting!
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Offline JR

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #895 on: March 22, 2019, 11:01:57 PM »
Spring plates on the housing?
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Offline Nate

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #896 on: March 22, 2019, 11:19:56 PM »
What kind of garbage is that?.....what is their reasoning for having the customer call and special order diodes and mini wiring harness.....after they already paid for what is marketed as a complete kit?

Or did i miss something?
Nate

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Offline wyorunner

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #897 on: March 22, 2019, 11:54:44 PM »
What’s the flavor of the winch Chief? That rear axles all done then? Sure is wee but nasty looking.... however I ain’t got much room to speak our frame needs a cleaning and painting....

You’re Doing great work Chief!

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #898 on: March 23, 2019, 06:31:34 AM »
I believe I told you about the diodes and even put a link to the instructions Chief. You don’t need their kit, just go to the store and buy some diodes. They are cheap.

Nate when I did mine it was because it’s only required on the 01-03 IRRC and not many people spend $1k on steps for a nearly 20 year old truck.


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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #899 on: March 23, 2019, 08:06:46 AM »
What kind of garbage is that?.....what is their reasoning for having the customer call and special order diodes and mini wiring harness.....after they already paid for what is marketed as a complete kit?

Or did i miss something?
No, Nate, You're right
I had the same sentiments when I got to that point and realized I was still days from finishing. Imagine if I was planning on driving to work on monday with that mess?
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