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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1150 on: June 06, 2019, 11:13:48 PM »
Back into the garage for some more fitting
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1151 on: June 06, 2019, 11:15:28 PM »
And after moving it I noticed this!!!!!!!!!!

Honestly, am I ever going to get actually finished??? :shocked:

Oh and did I mention there is no cold air coming out of the AC???!!! :facepalm:
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Offline Bigdave_185

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1152 on: June 06, 2019, 11:16:34 PM »
Time to part into it and start on the next one isn’t it?


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Offline cj7ox

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1153 on: June 07, 2019, 07:47:30 AM »
LOL! I had a Division run at oh dark thirty this morning, and the quoffee afterwards is necessarily strong.

I am so glad that I never had to spend any amount of time in Kuwait  :facepalm:  just the few days it took to get in and out of theater were bad enough.

Did you fly through Qatar? I personally would take Kuwait over Qatar, but I was also stuck in Qatar because of plane breakage issues.... for ten days. And then in Germany on the flight for about 7 hours. What a return trip that was! Thankfully I was traveling solo so I was able to be an anonymous blender inner!

I took a C-130 flight from salerno to Kuwait and we stopped in Qatar just long enough to off load some cargo and to refuel.

Ahh, ok that makes sense. Which is probably one of the better ways to go.

At least in Qatar you can drink beer. ;-)
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1154 on: June 07, 2019, 09:15:13 AM »
And after moving it I noticed this!!!!!!!!!!

Honestly, am I ever going to get actually finished??? :shocked:

Oh and did I mention there is no cold air coming out of the AC???!!! :facepalm:

Looks reddish, trans?
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1155 on: June 07, 2019, 10:31:37 AM »
Time to part into it and start on the next one isn’t it?


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Aren't you supposed to be banned or something? :-?
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1156 on: June 07, 2019, 10:33:00 AM »
And after moving it I noticed this!!!!!!!!!!

Honestly, am I ever going to get actually finished??? :shocked:

Oh and did I mention there is no cold air coming out of the AC???!!! :facepalm:

Looks reddish, trans?
Yea, that's my guess and initial investigation isn't good. Not conclusive, but looks to be coming from parting line between trans output and front of transfer.
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Online wyorunner

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1157 on: June 07, 2019, 10:50:14 AM »
And after moving it I noticed this!!!!!!!!!!

Honestly, am I ever going to get actually finished??? :shocked:

Oh and did I mention there is no cold air coming out of the AC???!!! :facepalm:

Looks reddish, trans?
Yea, that's my guess and initial investigation isn't good. Not conclusive, but looks to be coming from parting line between trans output and front of transfer.

Well if it is that location I’m going to be hopeful that it just needs a new gasket. Other than the heft of the transfer it is an easy job as you know.

Ours was leaking from the same spot, but I knew it was because there was no gasket between the two.

Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1158 on: June 07, 2019, 11:00:45 AM »
And after moving it I noticed this!!!!!!!!!!

Honestly, am I ever going to get actually finished??? :shocked:

Oh and did I mention there is no cold air coming out of the AC???!!! :facepalm:

Looks reddish, trans?
Yea, that's my guess and initial investigation isn't good. Not conclusive, but looks to be coming from parting line between trans output and front of transfer.

Well if it is that location I’m going to be hopeful that it just needs a new gasket. Other than the heft of the transfer it is an easy job as you know.

Ours was leaking from the same spot, but I knew it was because there was no gasket between the two.
More serious than that I think.
I believe the transfer has a seal on the input and the trans, one on the output.

Not sure, anyone know for sure?

I did put a new seal onto the transfer input, but I don't recall doing anything to the trans output. I installed a new gasket between the two
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Offline Bigdave_185

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1159 on: June 07, 2019, 11:02:36 AM »
Time to part into it and start on the next one isn’t it?


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Offline KensAuto

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1160 on: June 07, 2019, 12:10:02 PM »
The trans doesn't have an output seal. The input on the TC is the only seal. That whole cavity between the 2 is full of tranny fluid making the gasket mucho importante .
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Offline Nate

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1161 on: June 07, 2019, 12:20:18 PM »
I wonder if those bolts worked themselves loose during test drive and drive shaft issue?
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Offline EL TATE

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1162 on: June 07, 2019, 12:30:25 PM »
I wonder if those bolts worked themselves loose during test drive and drive shaft issue?

I was just thinking of this
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Offline KensAuto

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1163 on: June 07, 2019, 12:50:42 PM »
I wonder if those bolts worked themselves loose during test drive and drive shaft issue?
Or he used silicone on the gasket and the gasket squished out. may or may not be speaking from experience.  :embarrassed:
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1164 on: June 07, 2019, 09:40:57 PM »
I wonder if those bolts worked themselves loose during test drive and drive shaft issue?
Or he used silicone on the gasket and the gasket squished out. may or may not be speaking from experience.  :embarrassed:
I was waiting for the response to figure out what next.
So, I did install a new gasket that came with the transfer case pump fix kit. I don't recall putting any silicone on it. I'll look more closely at it.
So here is what the leak/seep/drip/whatever looks like:
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1165 on: June 07, 2019, 09:42:59 PM »
I can find nothing showing any evidence of fluid anywhere above the low point of the mating surface between the two components.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1166 on: June 07, 2019, 09:46:18 PM »
And after examining the photos, I don't see any silicone, so I think I'm correct in saying I just placed the gasket onto two clean surfaces.

So I didn't get any further into it for the moment as I was waiting for the brain trust to kick in with their advice.

And as per SOP, when one thing grinds to a halt, I start something else.

On the punchout list was, securing the line on the brake isolation valve. One clamp and that was done
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1167 on: June 07, 2019, 09:48:21 PM »
Then it was time to complete the wiring for the top mount back up light. I grounded it on the stoplight screw, then used adhesive blocks to route the wire from the tail light housing up to the light
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1168 on: June 07, 2019, 09:49:18 PM »
And now that is working and completed
« Last Edit: June 07, 2019, 09:50:32 PM by Flyin6 »
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1169 on: June 07, 2019, 09:52:09 PM »
Next up, I installed the 800 watt inverter. This is needed to power my computer, and perhaps some low amp draw something, maybe a fan...
It is wired to the aft battery only.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1170 on: June 07, 2019, 09:54:35 PM »
So, the way I did it was to run another hot battery cable into the passenger compartment to a homemade fuse block. I like the combustible stuff (Carryover from my welding days). I placed two 40 amp mega fuses onto the block to power the inverter and some unforeseen future something or another.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1171 on: June 07, 2019, 09:57:19 PM »
I mounted it on the forward bulkhead of the drawer cabinet and just behind the passenger seat. The inverter is positioned a bit more toward the center and below the door to the storage drawers.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1172 on: June 07, 2019, 10:00:03 PM »
The rear hatch opens just a bit too far to deploy the awning without interference. To remedy that, I fashioned up a simple strap to hold the hatch in a 80% open position.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1173 on: June 07, 2019, 10:01:26 PM »
A small section of pile allows for the strap to be stowed out of the way where it will not protrude when not in use
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1174 on: June 07, 2019, 10:02:44 PM »
You may not notice as some changes are subtle, but I am slowly adding provisions and stowing them here and there. The back end is filling up
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1175 on: June 07, 2019, 10:04:49 PM »
No, the weapon will not be going with us

I upgraded the toolbox with more stuff. I went from the 3"ish deep box to a 4.something inch deep box and added more spare hardware and some more tools.
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Offline KensAuto

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1176 on: June 07, 2019, 10:29:33 PM »
Can't remember on the 4l80s, but on the Allys,  when they blow fluid out of the transmission vent tube,  it will run down the left side and end up right where yours is wet. Something to look for.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1177 on: June 08, 2019, 08:46:54 PM »
Can't remember on the 4l80s, but on the Allys,  when they blow fluid out of the transmission vent tube,  it will run down the left side and end up right where yours is wet. Something to look for.
I'll look again ken, but after studying and examining it for some time, I did not see any evidience of any wetness anywhere above the low point I pointed out.

So on another point, I think I may have nicked or drilled into an AC line. I am getting no cool air at all, and I remember when drilling for the electric step bracket, the drill punching through and digging into that group of heater and AC lines which run along the inner rocker on the right side.

I will have to dig into that and see what is going on, and if that is why I do not have cooling. The compressor is cycling like it should...

The larger problem is that I have missed my launch date now by two weeks...with a rapidly closing window before pre-ranger number small has to start football practice...
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Offline KensAuto

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1178 on: June 09, 2019, 12:10:06 AM »
If the compressor is running,  it has freon. Is the drier getting cold?
Going out on a limb, but sounds like the temp door motor acting up. If so, it  probably had something to do with your dead battery issues.
..drier cold (40* ish) means problem is in the dash.
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Offline KensAuto

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1179 on: June 09, 2019, 12:13:42 AM »
Just remembered it had rear a/c. The back would still be cold even if the front temp door was acting up.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1180 on: June 09, 2019, 08:09:16 AM »
If the compressor is running,  it has freon. Is the drier getting cold?
Going out on a limb, but sounds like the temp door motor acting up. If so, it  probably had something to do with your dead battery issues.
..drier cold (40* ish) means problem is in the dash.
I'll check the drier out when I get back from church.
But no cold air at all coming out of dash vent
Rear discharge was not checked

So plan of attack today is to check that out, and look for that vent tube connection. I did find a rubber hose which was not connected to anything on the top of the transmission...

If the compressor is running and nothing else is amiss, then perhaps just needs a recharge. I never checked that out when the thing arrived here last fall.
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Offline swbhobie16

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1181 on: June 09, 2019, 10:06:10 AM »

.. I did find a rubber hose which was not connected to anything on the top of the transmission.

  :facepalm: hah

in all honesty.. i hope that’s it. would be a quick and easy solution to a leaky trans. especially with no other real suspects..

Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1182 on: June 09, 2019, 04:42:13 PM »

.. I did find a rubber hose which was not connected to anything on the top of the transmission.

  :facepalm: hah

in all honesty.. i hope that’s it. would be a quick and easy solution to a leaky trans. especially with no other real suspects..
OK, back from an awesome church service. Eyelid check complete...no holes!

Jockin' up with ma work clothes. gunna find out pdq...
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1183 on: June 10, 2019, 05:54:27 PM »
What in the tarnation is going on here? You get stuck in a KY mulch bed at the local piggly wiggly again?

Perhaps you were transporting Kens gf (hopefully to a big hole on the back 40) and blew out all four tires simultaneously?

Or you dropped it off at Dave’s cabinet shop for a hippy color makeover?

Yeah I know probably not but all of those above sounded better than going the way of SQ D.......  :facepalm:
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Offline KensAuto

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1184 on: June 10, 2019, 07:34:00 PM »
Harsh words my friend,  harsh words.
..especially the part about Dave.  Rofl
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1185 on: June 10, 2019, 07:49:04 PM »
I think I'm just going to take it to a transmission shop of to the local Ken's Auto place.

I wiped the trans area down really well, then only started it up for like 30 seconds on Sunday. Today, I see wet spots and a bunch of drips hanging on the crossmember. And I can't find the first leak from anywhere north of the bottom of the trans output flange.

So it doesn't look like I am going to get any sort of a break, and although I have been trying to save myself some money, Its time to just get it done so i can pull off some kind of trip. Honestly it is now doubtful that I have enough time to do the big trip I wanted to go on so much. Pre-Ranger little starts his varsity football team training in earnest 10 July. He has actually been in training all summer but that is the first day that is no longer optional. So do I take away his year of playing football? His first year in Highschool?

Back to the truck, I am trying to get it into the shop tomorrow morning.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1186 on: June 11, 2019, 11:53:26 PM »
Update: I am scheduled for 0830 on Monday to drop it off. I'm having the AC serviced/fixed and that trans oil leak attended to. After that I'll start to drive to record data.

This all means several things

First, It will be getting done and will be useable
Second, There is no longer enough time to do the big trip I planned. If we get it fixed by say, COB Tuesday, and record data the following two days, then sending it off to Justin, I'm betting it will still be a few days to a week before I get anything back.
The situation has forced me to alter the travel plans to something closer in even hub and spoke. Not sure how that will work out, but we will hopefully be getting something done on the camping front.

I'm a bit disappointed but after the past, month or so, almost somewhat relieved. I worked my butt off on that thing. It was just too much work for one guy and there were several things that had issues that backed me up by a couple weeks. That, some nasty weather, having to still work on the house, be a father, serve at church, and 44 other commitments made this what it is. Additionally we completely dismantled the SquareD project and sorted and sold all those parts to perhaps 20 different folks.

No real lesson learned here, it was a major undertaking and in short order I will start to drive one magnificent truck, but just not to Washington. I apologize to those who were planning to meet and greet this year. Hopefully I can be in a good position to leave on time next year.
« Last Edit: June 11, 2019, 11:54:00 PM by Flyin6 »
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Offline Bigdave_185

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1187 on: June 12, 2019, 01:12:33 AM »
I feel like Ken told you to not monkey with the rear axle!   Just sayin


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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1188 on: June 12, 2019, 01:48:48 AM »
You’ve built one heck of a vehicle Chief. Thankfully there’s still an opportunity to spend quality time with you two young men this year and y’all will have plenty of time to plan for a big adventure next year.


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Offline EL TATE

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1189 on: June 12, 2019, 11:39:41 AM »
I'm sure little Don and I will survive, not sure about Bob or Ryan :evil: we'll get lunch next summer, have fun with your boys where and while you can. they will be grown and gone soon.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1190 on: June 12, 2019, 08:10:37 PM »
I feel like Ken told you to not monkey with the rear axle!   Just sayin


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Well that's just it. We can always point to someone who told you so and so forth. At the end of the day we all make our own decisions because it is not for others to live our lives, we must.
I did what I wanted to do here and that's really all that matters. None of this is about making anyone else happy, satisfied or anything else. It is simply a progress report on the building of this Suburban. To that end, it is built.

As for me and the guys, something interesting has been happening. We all decided that we have neglected the house, and we should work on it. So every day we have been pouring over it, fixing everything in sight. In doing so we have been spending a lot of time together, talking, kidding around, eating, getting dirty and tired together. It seems trip or no, we are bonding pretty well.

And, whenever we do something, no one can really predict just how things are going to turn out. But it is important to note that this burb did turn out so to speak. I'm fairly certain that after this visit to Troy, my mechanic friend, the thing will get repaired correctly and I can do the data recording and the follow in tune. It is very close to being finished.
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1191 on: June 12, 2019, 09:39:41 PM »
For what it’s worth and regardless of what he might have said either way I will just blame Ken.

Why Ken you ask? Well, for starters that whole love affair with H.

Second the 1911 thing, I mean who still uses one of those?  :rolleyes: I mean why not blame him? I can’t come up with a single reason not to.

Then the fact we believe his middle name is Dave, yeah who knew right?!?

Oh, and he’s a fallen DOT member. I think Don even promoted him to just below a paid salary position. What the heck is with all that butt kissing anyhow?

So regardless of what all you other weak knee knuckleheads think I’m gunna just blame him for this debacle......
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Offline Bigdave_185

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1192 on: June 12, 2019, 10:40:52 PM »
I had awhole excuse of a second trip to Moab when Don came here to Moab!   I am just mad I can’t use that excuse to make a second trip. 


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Offline JR

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1193 on: June 13, 2019, 04:37:13 AM »
I understand Don, I have been doing the same.

When/if next year maybe I can tag along to moab. Never been, told the boys and need to be led around the first tine.
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Offline Bigdave_185

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1194 on: June 13, 2019, 09:08:57 AM »
He there is really quite a great trail system here,  there are very few trail obstacles that don’t have a bypass trail, a obstacle warning.    I was shocked at what a little common sense did with the two other drivers that hadn’t been here before chose to drive.   

I’d tour guide anyone if it worked with my schedule. 


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Offline cudakidd53

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1195 on: June 13, 2019, 11:43:39 AM »
Incredible amount of work done and improvements accomplished!  Your trip will be everything that it's supposed to be Don - God is in control!
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1196 on: June 14, 2019, 09:34:58 AM »
Yea, well, I feel like crap that I couldn't pull this off in time to make it happen. Maybe if the football thing didn't crop up, essentially killing off almost half of the summer I could still do it. But I can't take that boy's football aspirations away from him. He is successful out there. He is getting exposure to many strong men, and learning about payoffs from hard work, how to shake it off, and teamwork. That's a bunch of stuff and in my view it trumps what I wanted to do.
But I'm not throwing in the towel, I just have to repackage it and get the dad/son thing done within the fabric of the situation I have in front of me.

Shawn, you started something, and you're gonna be on your own with it. You criticized Ken's love for the venerable 1911 calling it out, well questioning it. My pre-ranger, small edition) owns one of those. His first pistol. He points out that when the glock served the US Army for many decades and won a world war, he will consider it a great weapon, but not until then. Now this young man is not going to stay a young man. He is getting bigger and stronger by the week. He will someday wear the rank of a US Army Officer (I think) with a gold tab on his shoulder that simply says, "Ranger." Now, I'd think twice about crossin' up one like that. And what if he ends up as your son in law? What then? Careful my friend where you tread or what you say. Words have a way of walking right up into your business if you know what I'm sayin' ;-)
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Online stlaser

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1197 on: June 14, 2019, 11:16:48 AM »
Still Kens fault somehow.....  :tongue:
Unretired, sweeping floor at GLO once again & making coffee.

Offline TexasRedNeck

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1198 on: June 14, 2019, 10:57:11 PM »
I’ll throw this out there. And I may live to regret it.  Anyone want to shoot a combat pistol course with a 1911 against me an a glock I have prizes for the winner. And it has to be muddy. . Jus saying. I ain’t afraid to pay up.


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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 TexasRedNeck

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1199 on: June 14, 2019, 11:13:26 PM »
Never-mind. That was an arrogant insensitive post.   I’m sure there are many who can outshoot me with a 1911. Or a glock or M&P or whatever.

My apologies.


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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.

Joshua 6:20-24