Project MULE - Expedition build on a 1991 1500 4x4 Suburban

[pma4x4]

Ebay user name?

roughneck556

PM me here and I can give you my contact info and we can go from there.

 

[campfire]

Whats up guys! Well The Mule is back. Sad story is it was parked over two years ago. occasionally used for some oddball job then parked again. It was then on the chopping block for a planned sale on it but after a while we thought we would keep it and continue with the powerplant upgrades.

Welcome back, eh? Nice to see this thing alive again.

Has the paint faded, or is that just the lighting?

 

[pma4x4]

Not lighting. The paint faded over the years. Going to repaint it when it warms back up. Going with a gloss grey.

 

[pma4x4]

Updates projects 12-4-2018
Check engine running temps (seems cold, could be sending unit (Bad temp info to ECM can cause bad MPG)
Ford Windstar fan upgrade
two temperature controlled fan circuits for Windstar fans.
12v 3 wire heated O2 sensor
Front door power window relay upgrade
Front door power window motor replacement
Front shock replacement
Adding dual inline steering stabilizer.
Add fresh coat of coo top to roof
Repaint truck to grey with black accents
Get roof rack powder coated
re-design control center in center console
Add Emergency LED amber and white LED strobes (for Skywarn "Weather chasing)
Undercoat the entire bottom side (pre-Minnesota move)

Powerplant upgrade (maybe before end of 2019)
EQ Vortec heads (55-87 bolt pattern)
Edelbrock Pro-Flo 4 EFI system
Headers
Camshaft & Lifters
Timing chain

 

[pma4x4]

Glad to see this getting some love and attention, it is a good old truck with a lot of life left in it.

Im trying to remember, i might just be forgetting. Greg weren't you the GMC4x4 forum creator? I noticed it's gone

 

[pma4x4]

Well. truck not start no more. Ignition cylinder has crapped out. so time to dive into the column... again. Luckily it crapped out parked in front of the garage so not bad. The last time I went into the column was to tighten it up which didn't turn out the way I hoped so this time I ordered a full column rebuild kit and a AC delco ignition key cylinder

 

[pma4x4]

Ok... You need a index for this build thread. You've done so many cool things I want look at again for ideas and we are up to 81 pages lol! =)

Well with the new forum format its only 59 pages now.

Yes once I am done fixing all the pics (currently at page 40) I plane to go back to the first page and create an index.

 

[pma4x4]

There are just a handful of posts with links to pics that are broken. I just need to find their sources but other then that ALL pics are fixed in this thread.

I will try index the thread this week.

Working the burb later this week. will get back to posting pics of the build and repairs as we move along

 

[pma4x4]

As many have requested I now have an index on the first post. I will also be offering the entire collection of build pics as a single zip file for download. There are many more pics that I never posted in this thread. That will be on the first post as well.

 

[pma4x4]

A part of bringing the burb back to life was flushing the fuel system out and rebuilding the TBI after sitting fro so long. I dropped the adjustable fuel pressure regulator and installed a fixed 14lbs spring. it measured a solid 13lbs maybe a hair above. IMO better than the adjustable one.

Can get the spring here.

Much better with new tires and wheels. I had to readjust the DRAC but not much.

Windows FINALLY getting a much needed upgrade! Going to need these things to actually work in sub arctic temps when we move back home! AC Delco window regulator motors found here

Dumping the clutch mechanicl fan for all electric fans. Went with the Ford Windstar fan setup. I just decided to get a new set from Dorman. Find the fans here

and because I left the hood cracked open hoping to reduce the desert rat camping the sun got to a lot fo the plastics including both jugs so Dorman to the rescue again. The Washer fluid jug is OEM style but the Coolant overlfow jug us universal square shaped.

Dorman washer jug link here
Dorman Coolant jug link here

Doing some test sanding spots on the body. Once it warms up she goes gloss grey.

 

[Big Ray]

Nice! Where did you get those window harnesses?

 

[pma4x4]

Nice! Where did you get those window harnesses?

The relay harness kit is a kit LMC Truck offers specifically for the front windows.

 

[pma4x4]

Not much for cool upgrades of late. just doing some basic in depth maintenance. Changing out the air cleaner, upgrading from the 1 wire o2 to a pre-heated 3 wire o2. found out the coolant temp sensor for the ECM was faulty so it was reading low which enriches the mixture given bad MPG. Gonna change out the thermostat while I'm there. Also turns out the idler pulley needs replacing and the steering column never really tightened up after my first battle with it 6 years ago. I want with a traditional 14" air cleaner. Pulled the "salad bowl" from the stock air cleaner and I added a Outters-wear prefilter which will helps immensely! These things kicked ass when I used them on my dirt bikes and ATVs in the desert. saved the filters a ton of wear and tear.

For the Windstar fan control I am going with two temp sensors and instead of trying to do some funky plumbing out of the 2 ports I have that are ALREADY in use I found a thermostat housing manifold that gives me what I need. I also did initial testing with the fans and I don't see any issues using a simple 40amp Bosch type relay. Just need to make sure the proper gauge of wire is used and keep wire length from battery to relay to fans as short as possible.

 

[pma4x4]

I sent my Christmas list off to Santa last night

 

[pma4x4]

The battle of the steering column repair begins. details and pics to come later... Had to order unexpected parts.

 

[Vasquez]

Interesting build. Following for updates on the efi. And Happy New Year!

 

[pma4x4]

Interesting build. Following for updates on the efi. And Happy New Year!

Yeah Santa never delivered the EFI. So it's what I have still for a while.

A big update will be coming here soon. Just been trying to get it all done and the last week has been reading almost the whole time I've been off.

 

[pma4x4]

ok this blows. All my pics for my fans and other projects have gone MIA. FAWWWWK!

 

[pma4x4]

Ok FINALLY! I found the pics. they were on an SD card and got ran thru the wash and dyrer a few times. They survived, thank god for solid state technology. The other reason why I'm so late to gettign this posted as I sold our Jeep Cherokee and got a 2002 S10 Ext cab so I've been hacing to get that some attention to get it up to a solid daily driver status. I got the S10 for 2 reasons. 1) I needed a better and larger sixed vehicle so I can use it for Amazon deliveries and I also plan to to Uber eats to pick up extra cash. 2) we will take it back with us to MN as a rust free truck and I plan to build it into a pro tour truck with a built LS6.0.

A few of these pics were before Christmas and after. You can see the pile of stuff I got planned and even may have installed by now. I have not done the power window upgrade mod yet. I plan to do that as a full write-up (hopefully).

 

[pma4x4]

Even after that first initail bolt tightening I did on the steering column back on '12 it was still loose. I finally snapped in December and got every single component new that I could get my hands on. The results... play is still there but far less. talked with a couple column repair shops and they both think its in the tilt locking mechanism itself. That's all that's left. I've replaced everything .
else.