I've got one of the tapered sleeves in the left side of my dana 44 and it works excellently. I cheated and had my friend using his mill to ream the hole out to 7/8 for the insert
CK5
Register an account today to become a member! Once signed in, you'll be able to participate on this site by adding your own topics and posts, as well as connect with other members.
'99 4 Door Tahoe SAS Build, Taking it back a few years
- Thread starter 4door99
- Start date
Nice build, dont see many geared toward trails in louisiana... Looking forward to some pictures and details on the trip to Blazer Bash, I'm hoping to make the trip from south la next year.
This build update is long overdue. In fact, it probably is going to be very lengthy. But for you guys who don’t care to read, or just don’t care, I’ll be sure to include lots of pretty pictures. I’ll try to keep things about the Blazer Bash itself pretty short, because that was covered in detail throughout the BB thread.
Anyway, I got so busy with the truck, trying to get it ready for the Blazer Bash trip, and work has been CRAZY since I have returned, that I’m just now getting a chance to update this thread. And even though the Blazer Bash trip was well over a month ago, I’m still buzzing for the whole experience. So it’s time to get caught up:
Well like I said, things were hectic the last weeks before the start of the trip. And the biggest hiccup was that the “security key” in the steering column decided to go out. Would not crank! Or would crank and then die! It turned out to be a nightmare to diagnose. And for a bit, I thought I wasn’t going to make the trip. My fix was that I ended up replacing EVERYTHING! The wiring harness, the key, the key tumbler, and the tumbler housing.
Needless to say, because of these problems, some things had to get put on hold. I never got around to installing the bump stops. I had a noisy, and weak, power steering pump that never got addressed. My tires still weren’t balanced correctly. But it was as ready as she was going to be.
Now remember, I’m driving this to Moab (1200 miles away), doing 3 days of Blazer Bash, and driving what’s left back home.
I allowed myself plenty of time, 2 weeks off work to take it easy getting out there and plenty of time to get it back after the event. Ended up taking my girlfriend, Melissa, along with me. I was very fortunate that here job allowed her enough time off to go, and I’m glad she did!
We spent a total of 3 ½ days driving and taking it easy to get to Moab. And surprisingly, the Tahoe traveled very well (with the exception of an out of balance tire). We were able to get there a couple days early, which was great. The first full day in Moab we spent checking out Arches National Park. And that is a MUST SEE!
After doing the tourist thing, we teamed up with a few of the new arrivals to BB on Thursday and hit my first trail in Moab… Flat Iron Mesa.
Well, we had an amazing time and the Tahoe really was preforming great, way better than I even expected. Only had a couple of issues on this day: One was that the transfer case kicked itself out of low into neutral on one of the hill climbs (scary for a moment). I figured it had to be an issue with the shift linkage binding as the body twisted, so I didn’t pay it too much attention. I also ended up cutting a tire sidewall. The Old military surplus tires I was running were also starting to show a little dry rot when aired down, and their age probably had to do with the weak sidewall and me not being able to get them to balance.
Friday, and the first official day of the Blazer Bash, was spent with the majority of the group at Hells Revenge. It was like being on another planet. And there was a lot of trucks! They snaked through hells for as far as you could see. Very fun experience and I will do this again. The Tahoe gave me no issues at all throughout the Hells trip, and preformed like a champ. Very proud of the build so far.
![IMG_4858[1].JPG](https://ck5.com/forums/data/attachments/196/196072-44a305a713c2947f7835308231863674.jpg "IMG_4858[1].JPG")
![IMG_4857[1].JPG](https://ck5.com/forums/data/attachments/196/196073-9c9a6c9bafdf298b159c275190ae36fd.jpg "IMG_4857[1].JPG")
![IMG_4664[1].JPG](https://ck5.com/forums/data/attachments/196/196076-dbf070e591e53c47c462cf7b4af86b24.jpg "IMG_4664[1].JPG")
Now comes Saturday, and this is where things got interesting. I was scheduled to run Fins and Things, which was to be a fairly easy trail and not very lengthy. I wanted to wheel the whole day, and up the challenge just a bit from “easy”. My remaining choices were Cliff Hanger (difficult), Pritchett (extremely difficult), or Golden Spike (challenging and lengthy). I went with Golden Spike. Now there were only 4 total trucks on this trail, which was great because we were able to keep a good pace. And the trail did have some challenges, but the Tahoe was handling them very well. And I had an awesome trail leader and spotter, @ktmoutfront (aka: Wade). So things were looking great. Well, what I have failed to mention was that the T-case popping out of low into neutral had continued to happen. And I couldn’t make it do it. It would just randomly pop out and the most annoying times. Still no big deal right? Just kick it back into gear and continue moving. Along with this, my confidence level in machine and myself had also started getting a little out of hand, taking more difficult lines and really starting to push the Tahoe. Combine those two issues, and disaster was approaching.
![IMG_4681[1].JPG](https://ck5.com/forums/data/attachments/196/196079-1460ffb1fa8a1c7b82edac4950f89c98.jpg "IMG_4681[1].JPG")
![IMG_4679[1].JPG](https://ck5.com/forums/data/attachments/196/196080-d69221f7931355ae07722589e20ae4fe.jpg "IMG_4679[1].JPG")
Got hung up on a hill (can’t remember the name but it damn sure had one) and I just needed that one good bump to get over this one ledge. Well, every time I bumped it, just a little harder than the last, the T-case would kick out of low. Frustration hits, too much throttle, and BAM!! Slip yoke, 2 U-joints, and the pinion yoke all broke at once. And made the view for the remaining 3rd of the trail look like this:
Thanks again to Wade for dragging the 7000 pound Tahoe up and around every remaining obstacle.
Well, got it back to camp and the hunt for parts and repairs began. I used the thread and put out a search for the yokes. @Truckman4life came to the rescue and had what I needed, so I rushed to his place. Now, I had in mind I was just going to buy a part or two from a guy who had them and was offering them up to help a fellow wheeler out. What I didn’t expect was him to offer up himself, his garage, his tools and driveway to get my Tahoe back going. What a great person, and I’ll forever be in debt.
So the Tahoe is back in business and ready for one more trail. So Sunday, we went with Wade and another small group and did Steel Bender.
![IMG_4685[1].JPG](https://ck5.com/forums/data/attachments/196/196081-e35d8d05a611ee94c5741c4260370ae7.jpg "IMG_4685[1].JPG")
![IMG_4668[1].JPG](https://ck5.com/forums/data/attachments/196/196082-80816a5d0cf36d62aa54c08768daab84.jpg "IMG_4668[1].JPG")
Not a hard trail, but I was so gun-shy from the day before. So even the simplest obstacle turned into a nail biter. I still had the T-case popping out issue and now a new driveline vibration. But it was a fun trail and we made it through. Got some great pics too!
![IMG_4669[1].JPG](https://ck5.com/forums/data/attachments/196/196083-3b28efb757699a9dce643163dad0f94f.jpg "IMG_4669[1].JPG")
![IMG_4689[1].JPG](https://ck5.com/forums/data/attachments/196/196084-d8efa807076ddf6d3b1bd15cf3525bed.jpg "IMG_4689[1].JPG")
When I got back to camp I investigated the driveline vibration further and found a bit of an issue. When I was at home, I was fighting rear driveshaft vibration and stacked shims under the springs to adjust the pinion angle. I ended up lowering the t-case and it fixed the problem before I made the trip. Well, I never removed the stacked shims and they had worked their way loose causing the u-bolts to become loose. The loose u-bolts actually caused the front edge of the spring perches to roll or bend down. Very bad! This was another one of those issues that I didn’t have time to address before we left, but should have! Anyway, here’s me with the help of @ChrisPerry aligning the rear end after kicking out the stacked shims to re-tighten the u-bolts.
![IMG_4766[1].JPG](https://ck5.com/forums/data/attachments/196/196085-471d2375ca8b31063bbcb334fa45e3f5.jpg "IMG_4766[1].JPG")
Blazer Bash was over and it was time to work our way back home. Had plenty of time, so once again we took the scenic route. We ended up in Silverton, CO. From there we figured we’d cross Engineer Pass over into Lake City. And that’s where I discovered a new problem. Half way up to the pass, at about 11,000 feet in elevation, the road got a little rough and steep. No problem, just came from Moab, so this was nothing. Except that when I reached to pull it into 4x4 low, the shifter hung between selections. And it was hung badly! Something broke inside the T-case. It took me 20 minutes to get it unstuck and all I was able to find again was 2 high. So, we continued on, slowly, letting the Detroit Locker do the work and cooling the trans every few hundred feet.
![IMG_4692[1].JPG](https://ck5.com/forums/data/attachments/196/196086-e7652fe84ffaa1af068e74457dff353a.jpg "IMG_4692[1].JPG")
I got the Tahoe down and back on flat ground. The T-case held fine in 2wd high, and gave me no more trouble on the way home. But I made damn sure not to reach and grab that shifter again!
Now I mentioned all the problems the Tahoe had, but I’m really very proud of it! The thing did every bit of what I hoped it would do, and much more. Drove half way across the country, wheeled for 4 very hard days on trails more difficult than I ever expected, and it got me back home. And I haven’t even had time to fix the issues that developed from the trip, but I still drive it almost every day. I’ve got that brand new truck with the big payment sitting in the driveway, that everyone around here thinks is a must have. But I still rather drive the 18 year old Tahoe! It must be a sickness? And no matter what I change, or what upgrades I end up doing, it will always be a driver.
Now obviously, there are several things that need to be addressed, and upgrades I feel it needs before its next outing. So these are the next steps:
1. The T-case! A fresh NP241 with slip yoke eliminator. The SYE is a MUST DO upgrade because loosing fluid or constantly trying to find ways to stop the leak when the rear driveline is removed SUCKS!
2. Built front and rear driveshaft. Strong one’s that I can feel confident about.
3. New rear spring perches. Because mine aren’t flat anymore..
4. New tires. Rolled the dice on the old military surplus set. But fresh rubber is the only way to go at this point!
5. Hydro assist steering. The stock and weak power steering was no fun! I constantly wrestled with it. And it got me in a bind a couple of times. Don’t need any more of that!
The above list is certainly next for the Tahoe. And of course, it won’t be where it stops. I’ve got big plans for this thing. But I’m gonna need the check book to recover just a bit.
Anyway, I got so busy with the truck, trying to get it ready for the Blazer Bash trip, and work has been CRAZY since I have returned, that I’m just now getting a chance to update this thread. And even though the Blazer Bash trip was well over a month ago, I’m still buzzing for the whole experience. So it’s time to get caught up:
Well like I said, things were hectic the last weeks before the start of the trip. And the biggest hiccup was that the “security key” in the steering column decided to go out. Would not crank! Or would crank and then die! It turned out to be a nightmare to diagnose. And for a bit, I thought I wasn’t going to make the trip. My fix was that I ended up replacing EVERYTHING! The wiring harness, the key, the key tumbler, and the tumbler housing.
Needless to say, because of these problems, some things had to get put on hold. I never got around to installing the bump stops. I had a noisy, and weak, power steering pump that never got addressed. My tires still weren’t balanced correctly. But it was as ready as she was going to be.
Now remember, I’m driving this to Moab (1200 miles away), doing 3 days of Blazer Bash, and driving what’s left back home.
I allowed myself plenty of time, 2 weeks off work to take it easy getting out there and plenty of time to get it back after the event. Ended up taking my girlfriend, Melissa, along with me. I was very fortunate that here job allowed her enough time off to go, and I’m glad she did!
We spent a total of 3 ½ days driving and taking it easy to get to Moab. And surprisingly, the Tahoe traveled very well (with the exception of an out of balance tire). We were able to get there a couple days early, which was great. The first full day in Moab we spent checking out Arches National Park. And that is a MUST SEE!
After doing the tourist thing, we teamed up with a few of the new arrivals to BB on Thursday and hit my first trail in Moab… Flat Iron Mesa.
Well, we had an amazing time and the Tahoe really was preforming great, way better than I even expected. Only had a couple of issues on this day: One was that the transfer case kicked itself out of low into neutral on one of the hill climbs (scary for a moment). I figured it had to be an issue with the shift linkage binding as the body twisted, so I didn’t pay it too much attention. I also ended up cutting a tire sidewall. The Old military surplus tires I was running were also starting to show a little dry rot when aired down, and their age probably had to do with the weak sidewall and me not being able to get them to balance.
Friday, and the first official day of the Blazer Bash, was spent with the majority of the group at Hells Revenge. It was like being on another planet. And there was a lot of trucks! They snaked through hells for as far as you could see. Very fun experience and I will do this again. The Tahoe gave me no issues at all throughout the Hells trip, and preformed like a champ. Very proud of the build so far.
Now comes Saturday, and this is where things got interesting. I was scheduled to run Fins and Things, which was to be a fairly easy trail and not very lengthy. I wanted to wheel the whole day, and up the challenge just a bit from “easy”. My remaining choices were Cliff Hanger (difficult), Pritchett (extremely difficult), or Golden Spike (challenging and lengthy). I went with Golden Spike. Now there were only 4 total trucks on this trail, which was great because we were able to keep a good pace. And the trail did have some challenges, but the Tahoe was handling them very well. And I had an awesome trail leader and spotter, @ktmoutfront (aka: Wade). So things were looking great. Well, what I have failed to mention was that the T-case popping out of low into neutral had continued to happen. And I couldn’t make it do it. It would just randomly pop out and the most annoying times. Still no big deal right? Just kick it back into gear and continue moving. Along with this, my confidence level in machine and myself had also started getting a little out of hand, taking more difficult lines and really starting to push the Tahoe. Combine those two issues, and disaster was approaching.
Got hung up on a hill (can’t remember the name but it damn sure had one) and I just needed that one good bump to get over this one ledge. Well, every time I bumped it, just a little harder than the last, the T-case would kick out of low. Frustration hits, too much throttle, and BAM!! Slip yoke, 2 U-joints, and the pinion yoke all broke at once. And made the view for the remaining 3rd of the trail look like this:
Thanks again to Wade for dragging the 7000 pound Tahoe up and around every remaining obstacle.
Well, got it back to camp and the hunt for parts and repairs began. I used the thread and put out a search for the yokes. @Truckman4life came to the rescue and had what I needed, so I rushed to his place. Now, I had in mind I was just going to buy a part or two from a guy who had them and was offering them up to help a fellow wheeler out. What I didn’t expect was him to offer up himself, his garage, his tools and driveway to get my Tahoe back going. What a great person, and I’ll forever be in debt.
So the Tahoe is back in business and ready for one more trail. So Sunday, we went with Wade and another small group and did Steel Bender.
Not a hard trail, but I was so gun-shy from the day before. So even the simplest obstacle turned into a nail biter. I still had the T-case popping out issue and now a new driveline vibration. But it was a fun trail and we made it through. Got some great pics too!
When I got back to camp I investigated the driveline vibration further and found a bit of an issue. When I was at home, I was fighting rear driveshaft vibration and stacked shims under the springs to adjust the pinion angle. I ended up lowering the t-case and it fixed the problem before I made the trip. Well, I never removed the stacked shims and they had worked their way loose causing the u-bolts to become loose. The loose u-bolts actually caused the front edge of the spring perches to roll or bend down. Very bad! This was another one of those issues that I didn’t have time to address before we left, but should have! Anyway, here’s me with the help of @ChrisPerry aligning the rear end after kicking out the stacked shims to re-tighten the u-bolts.
Blazer Bash was over and it was time to work our way back home. Had plenty of time, so once again we took the scenic route. We ended up in Silverton, CO. From there we figured we’d cross Engineer Pass over into Lake City. And that’s where I discovered a new problem. Half way up to the pass, at about 11,000 feet in elevation, the road got a little rough and steep. No problem, just came from Moab, so this was nothing. Except that when I reached to pull it into 4x4 low, the shifter hung between selections. And it was hung badly! Something broke inside the T-case. It took me 20 minutes to get it unstuck and all I was able to find again was 2 high. So, we continued on, slowly, letting the Detroit Locker do the work and cooling the trans every few hundred feet.
I got the Tahoe down and back on flat ground. The T-case held fine in 2wd high, and gave me no more trouble on the way home. But I made damn sure not to reach and grab that shifter again!
Now I mentioned all the problems the Tahoe had, but I’m really very proud of it! The thing did every bit of what I hoped it would do, and much more. Drove half way across the country, wheeled for 4 very hard days on trails more difficult than I ever expected, and it got me back home. And I haven’t even had time to fix the issues that developed from the trip, but I still drive it almost every day. I’ve got that brand new truck with the big payment sitting in the driveway, that everyone around here thinks is a must have. But I still rather drive the 18 year old Tahoe! It must be a sickness? And no matter what I change, or what upgrades I end up doing, it will always be a driver.
Now obviously, there are several things that need to be addressed, and upgrades I feel it needs before its next outing. So these are the next steps:
1. The T-case! A fresh NP241 with slip yoke eliminator. The SYE is a MUST DO upgrade because loosing fluid or constantly trying to find ways to stop the leak when the rear driveline is removed SUCKS!
2. Built front and rear driveshaft. Strong one’s that I can feel confident about.
3. New rear spring perches. Because mine aren’t flat anymore..
4. New tires. Rolled the dice on the old military surplus set. But fresh rubber is the only way to go at this point!
5. Hydro assist steering. The stock and weak power steering was no fun! I constantly wrestled with it. And it got me in a bind a couple of times. Don’t need any more of that!
The above list is certainly next for the Tahoe. And of course, it won’t be where it stops. I’ve got big plans for this thing. But I’m gonna need the check book to recover just a bit.
It was great meeting you and the GF, Chad. It seems like you had one hell of an adventure, something not everyone gets to have.
if you don't remember, I'm the grey blazer/soft top/tube doors/dumbo mirrors
if you don't remember, I'm the grey blazer/soft top/tube doors/dumbo mirrors
Well it was great meeting you too Brent. And of course i remember. You had one of my favorite K5's at Bash!
Glad you had fun. Fixing the broke things are all abut the memories, as long as they fix that is.
Good stuff and nice truck! I love the fact you drove all the way to BB, I've wanted to go for years but when you're looking at literally thousands of miles for the round trip from this side of the country it just doesn't seem feasible/practical (driven or trailered). Do you think you'll try to go back sometime?
Glad I was able to get you back on the road/trail and that you had fun and made it home in one piece. It was great to meet you guys and hope to see you at next year's Blazer Bash. I too will be traveling for that one since I am moving out of state. I love your Tahoe and wouldn't mind having one like it for myself.
That answer is YES! I will go back. Working on plans for next year right now.
Excellent update! Looks like all the hard work paid off that is one nice Tahoe. Hopefully make it to a blazer bash in the future and check it out in person.
These things kinda have a way of endearing themselves to you despite the fact they break. Was great to meet you (and a fellow Tahoe enthusiast) and look forward to next year.
Awesome update! I love your rig. I've always wanted the exact same thing.
thanks for sharing the trip report.
Sounds like it was an awesome trip!
Sounds like it was an awesome trip!
Ten_Bucks
1/2 ton status
Hey @noJeepshere, you and @4door99 should come out to California and do a Rubicon run. Just like our trip from earlier this year but with two Tahoes/Yukon's. I think it'd be fun.
Scott
Scott
That would be fun.
The Rubicon is on my bucket list. I would certainly need time to plan and make that trip. Its nearly 2,000 miles away from my garage. But I will eventually make it out there.
Ten_Bucks
1/2 ton status
Let me know when you're ready to make it happen. I can be your tour guide just like I was for @noJeepshere. Hopefully by then I'll have a rig built so I don't have to just ride shotgun and be a spotter.
Scott
Hitting my first trail since the Moab trip this weekend. There's a local park about 40 miles out of town that I have never been to. Got an invite from a guy at the local fab shop to go show me around the place. Nasty weather is coming, but we're hoping to get at least a half day in wheelin before it hits. I've only fixed a couple of things on the Tahoe that needed to be addressed, but it should be fine. Will report how it went later this weekend.
Have fun!
