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First Project Ever

DarkandShiny

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Joined
Jun 26, 2012
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Location
Utah
Okay here is my first project truck ever. I really wanted an old box suburban. My friend had one when we were in high school and we explored a lot of the Utah wilderness in it. Now that I've got my own kids I'd like to make some memories doing the same thing with them.

Here is the story from the beginning. My Hyundai Elantra that my wife and I purchased new when we were in college finally kicked the bucket at just shy of 200,000 miles. I sold the car for 2k and was looking for a new vehicle. My wife insisted that I buy something nice like an Acura or go get a new Suburban to haul the kids around. I went to the Chevy dealership and looked at a new Burb. To my dismay the price for a new Suburban with 4 wheel drive came to $59,000 after taxes! Also I think the truck is ugly; it looks like an electric shaver to me. I'm sure it is a great piece of engineering and does lots of amazing things, but for 60k I want something that really speaks to me.

Surely for significantly less than 60K I can build a Suburban that I would be proud to own, is unique (like its owner), with the on and off road performance I require to drive everyday and take my wife and three kids (one more on the way) camping and explore the Utah wilderness. After a few months of searching I found myself in Los Angeles on business with a rental car and a flight home out of Las Vegas. So I searched the Craig's list ads and found a 1989 3/4 ton Burb in Hesperia California (right off I-15 and on my way). I paid the seller his asking price of 2,500, dropped of my rental car, and drove my new Suburban home 650 miles without incident.

Here she is without me touching her yet.
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The interior needs a lot of love. On a scale of 1 to 10 with 10 being the best I would say it is a 4. It isn't readily apparent how dirty and old the interior is by the photos
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So the first thing on my list was to get the Suburban (no name yet) to pass safety and emissions. I knew passing the safety test was going to take some work as the only issue I had driving home was that the truck wandered all over. The steering was very loose. I also heard an exhaust leak out of the manifold/header on the right side. I had no idea if the truck would pass emissions but I got about 15 MPG on the ride home (going 65).

So to fix the steering issue and catch up on some regular maintenance that I wasn't sure had been done recently I did the following:
  • oil and filter change - It looked like the truck was 4 quarts high!
  • New plugs
  • New wires
  • New distributor cap
  • New distributor rotor
  • Replaced the steering box
  • replaced the exhast manifold gasket
  • replaced oxygen sensor
  • replaced the serpentine belt
  • replaced both lower ball joints
  • replaced both upper ball joints
  • reapced the front wheel bearing
  • replaced the sway bar bushings
  • replaced the oil dipstick tube
  • filled it with coolant
  • replaced the gear oil in the rear diff
  • replaced the inner tie rod
  • filled it with transmission fluid (looked empty!)

That got me to the point where it felt more comfortable to drive it since it doesn't wander like it used to and it passed safety and emissions!

So now that it is running well and registered I can do an evaluation and set some goals for this project. The truck is in amazing shape - No Rust! Well i haven't found any rust. The truck's exterior is in amazing shape as is the under carriage.
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The things that I like about the truck:
  • Rust free (so far)
  • 3/4 ton
  • tailgate - I don't think I would have made a purchase if it had barn doors
  • no previous mods - bone stock except for a pair of headers
  • relatively low miles - there isn't a six digit odometer but it looks like there is only 106k miles on the truck
  • Mechanically in good shape, good enough to pass safety and emissions with minimal work

There are somethings I don't like about the truck:
  • Interior is in below average shape
  • It is only a 3 speed automatic
  • only a 14 bolt semi float
  • no tachometer, just a huge fuel gage where one should be

I will be posting lots of questions to my fellow brothers and sisters on this board. This truck will essentially become "The Suburban that CK5 Built" as I won't do anything without consulting with the experts here.

Thanks for reading - DS
 
I did a compression test of the engine

  • Cylinder 1 = 115
  • Cylinder 2 = 104
  • Cylinder 3 = 85
  • Cylinder 4 = 110
  • Cylinder 5 = 110
  • Cylinder 6 = 100
  • Cylinder 7 = 110
  • Cylinder 8 = 115

Any thoughts on what I should do with cylinder 3? Do products like engine restore work?

Getting a quote on a new tranmission today. I need more than 3 gears!.
There are about 100 miles of I-15 between Salt Lake City and St. George Utah where the speed limit is 80 MPH. My poor 3 speed isn't capable of keeping up.
 
I have used engine restore with success before but you have to use it every few oil changes.
 
First of all, sweet find! Love the 89-91 3/4 tons.

Miles: pull a carfax and see how often it was registered/looked at. You can sometimes tell each time it's rolled over. I counted my 89' and came up with 324,000 miles.

Don't know if it's possible but in 91' (only) they used the 4 speed tranny in the 3/4 suburban. Perhaps you can find one out there and drop in?!? Don't know how easy/hard that would be though?

You'd be surprise how much some water and soap can clean up that interior! I was NOT shy on pretty much soaking the seats to srub them down. They now look a TON better. Also, before hand, carb cleaner can do wonders on grease stains on carpet and seats. I used so much I thought I was going to pass out! Followed it with a good soap and water scrub and WAY better!

If you do want to replace your interior carpet www.stockinteriors.com is a good source.

I assume you already did your ball joints. If you get back in there, you might consider new axle shaft u-joints too.

Brakes.....be sure they are good and solid! New calipers are so cheap I'd just drop in new ones.

Good luck!
 
nice clean rig man! thats some pretty decent mileage for a truck without OD.
 
Okay - A six foot long box arrived at my office today.

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I feel like a kid at christmas. I'll be replacing all the internals (the ones that need replacing anyway) for the passenger side rear door. I will also be replacing my steering shaft as I received the part from Borgeson today. I will document all my work and post the photos this weekend.
 
Here is my new Borgeson steering shaft - Officially this is my first 'upgrade' as all my other parts have been stock replacements. I'm super stoked about getting all these goodies on this weekend.

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How do you feel about a manual swap? An NV4500 or possibly an NV3500 would be an upgrade over that TH400 and have overdrive.

Are you ditching the running boards?

Martin
 
How do you feel about a manual swap? An NV4500 or possibly an NV3500 would be an upgrade over that TH400 and have overdrive.

Are you ditching the running boards?

Yes running boards will be gone as soon as I get some time. I wanted to do a bunch of stuff this weekend but it snowed like crazy and I wasn't too keen on lying on my back in the frozen slush.

I am open to a manual swap - I kinda wanted an automatic but price is becoming an issue. Five gears is better than the three that I have.
 
The pile of parts for my truck is really piling up. Got this in the mail today to do the rear doors.

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Okay after taking a sawsall to a couple of pins in the rag joint, I finally got the old steering shaft off. One of the most difficult aspects the removal was getting the universal joint off the steering column. It was very tight and took me a long time to finally yank it off. I know hate that old steering shaft with a hateful hate.

So my new Borgeson shaft, part # 935, has been waiting patiently to be installed.... But it won't fit.

I can't get either of the ends to slip on. The steering box end seems to almost fit but I can't get it to seat. The Double D end of the steering column also seems a hair too big and wont slide into the female end of my new shaft. A lastly, the shaft is too long - I wasn't aware that I would have to cut this down myself.

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Thoughts??? I need help from the brotherhood.
 
Is this your build thread DNS? If so SUBSCRIBED!

Nice clean score on the burb, the interior shots I almost thought you stole from me! :D:D

I dont know what your full intent is with the steering shaft nor do I have an answer for you but you can always do a shaft swap in from a Jeep Cherokee (XJ small boxy one). I got a friend that has started a Cherokee yard/repair shop and I am thinking of buying all the shafts from him and when he gets more in and offer them up to CK5ers.
 
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I am thinking of buying all the shafts from him and when he gets more in and offer them up to CK5ers.

Not a bad idea. I paid more than $200 for a new Borgeson unit and I'm going to have to cut the shaft down anyway. Let me get you the link for the XJ Steering shaft thread.
 
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I am thinking of buying all the shafts from him and when he gets more in and offer them up to CK5ers.

Not a bad idea. I paid more than $200 for a new Borgeson unit and I'm going to have to cut the shaft down anyway. Let me get you the link for the XJ Steering shaft thread.

beat me to it...best $25 you'll spend on your rig

here's the write up :thumb:

http://coloradok5.com/forums/showthread.php?t=169874
 
Had to cut my Borgeson shaft down as well. But....it makes a huge difference if you have the rest of the front end dialed in ie: ball joints...tie rods...drag link...etc.
 
Great looking Sub!
On the 4 speed transmission, you could do a 4L80e conversion. It would be easiest to swap out the entire engine controll system - ECM (PCM includes the trany controll), wireing, sensors with one from a 1991. Alternatively, you could look into a gear vendors overdrive unit or swap in a 4L80e with a piggyback controller.
 

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