1989 GMC Suburban "Trail Boss" conversion

[warrpath4x4]

pulled the transfer case over the last couple evenings, I kind of expected to see more of a sign of fluid in between the case and adapter considering there was about a gallon of trans fluid in the transfer case. I didnt see any visible damage to the seal but the rubber was pretty hard. Picked up the needed seals last night, going to replace the input and both outputs since its out.

 

[warrpath4x4]

Cleaned about 10 pounds of grease, oil, dirt, and mud off the transfer case and the skid plate. Changed out the input and both output seals and got it reinstalled.

 

[warrpath4x4]

The driver window has not worked since I bought the suburban, I put a new window switch in (as it was hanging from the door) but it didnt fix the window. I bought a new motor a while back and finally got around to installing it tonight. Did some testing first, pulled the window switch and tested the wires at the switch to make sure power was going out, pulled the motor and regulator, with the motor in my hand and hitting the switch i could feel it click but no movement. I had planned on adding relays to the window motors to speed them up but this new one moves pretty quickly and i didnt even grease the track. Now I need to order two more for the passenger side as they are really slow.

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[warrpath4x4]

Yesterday was my birthday and I got exactly what I was wanting... time to work on the suburban.

Changed the oil for the first time since owning it (not that I've put that many miles on it)
Changed the trans filter and pan, the old pan was leaking around the gasket from being over tightened before

this little bastard was a pain to get out

The fill plug on the rear axle had been rounded out so I welded a bolt to it... and broke the bolt

So I welded a castle nut to what was now sticking out and was able to get it out, surprisingly the rear diff wasn't that low

The new front output shaft seal on the transfer case had already started leaking after a 2 mile drive so I pulled the seal and got another new one to put it. The design has has been updated from the old one and I put it in flush with the case but I think it needed to be seated in further. If it starts to leak again I know I can order the old style online.

Then drove the suburban into town for some fresh gas and wash the windows lol.

 

[joshuak]

Yesterday was my birthday and I got exactly what I was wanting... time to work on the suburban.

Happy Birthday!

Good job getting that fill plug out.

Then drove the suburban into town for some fresh gas and wash the windows lol.

Clean windows are worth the effort, definitely underrated in my book.

 

[warrpath4x4]

Happy Birthday!

Thank you

 

[DrSmash]

Happy Birthday

 

[warrpath4x4]

Happy Birthday

Thank you

 

[warrpath4x4]

The second front output shaft seal is leaking again, this time it took about 20 miles to start instead of 2. when looking up the seal all the auto part stores update to a dual lip seal

I found this original part number one from Global Transmission, so after I get back from taking the scouts to summer camp, I get to pull the front driveline AGAIN

 

[imiceman44]

The second front output shaft seal is leaking again, this time it took about 20 miles to start instead of 2. when looking up the seal all the auto part stores update to a dual lip seal

I found this original part number one from Global Transmission, so after I get back from taking the scouts to summer camp, I get to pull the front driveline AGAIN

Did you check if there's any play in the output shaft?
That usually causes the seals to go out too quick.

 

[warrpath4x4]

Did you check if there's any play in the output shaft?
That usually causes the seals to go out too quick.

Ya it feels solid and the original seal didn't leak, I only replaced it cause I had the case out. Probably should have just left it alone lol

 

[DrSmash]

Have you taken the rear output seal housing off? Or just prying out the seal out of the output housing?

 

[fastazz81]

Happy belated birthday

 

[warrpath4x4]

Have you taken the rear output seal housing off? Or just prying out the seal out of the output housing?

the rear I just pried the seal out

 

[warrpath4x4]

Happy belated birthday

Thank you

 

[DrSmash]

the rear I just pried the seal out

Oh duh yeah front output.

 

[warrpath4x4]

Got back from taking my kids scout troop to summer camp last week, put the new (old style seal) in and it is still seeping. The leak is no where near what it was before but this time i checked the yoke better and there is a small wear ring. Last night I ordered a speedi-sleeve for the yoke thats suppose to be here tomorrow. Luckily this time I did not put the driveline back in lol.

 

[warrpath4x4]

After driving to town and back a couple times, the seal has quit seeping. I will probably still put the speedi-sleeve in since there is a groove in the flange.

 

[warrpath4x4]

the steering still wanders a bit and I know i need to replace the ball joints but I had the wife go out last night and saw the steering wheel back and forth so I could watch the steering linkages and box/frame. She opens the door, "did you have this detailed?" no "did you detail it?" no i just vacuumed it "it came out really clean" lol

 

[warrpath4x4]

noticed the water pump was weeping, so threw a new pump and belt on.

also the other day when i had the wife turn the wheel for me I noticed there is play in the sector shaft coming out of the bottom of the box. I gave the adjusting bolt a 1/4 turn and it drives much better now. I know its not a permanent fix, when I put the dana 60 in the stepside with crossover steering I will put the box from there in here as I know its a good box.