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The Green Machine - parked

noJeepshere

I Drove Trains!
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Ok, so I've planning on doing an axle swap into my 99 GMC Yukon for quite some time now, and I figure I better post up so all y'all can follow along. My Yukon has put in many years of reliable service as a daily driver, which is partly why it's been kept mostly stock and on mild mannered street tires so far. However, that's about to change. You see, the ol girl has quite a few miles on her, the engine is strong and the trans still acts like the day it was made, but the axles and most of the suspension components (especially the front IFS) are shot. So, I could either spend a lot of money lifting it and putting big meats on GM IFS, or spend about the same amount and put in some one ton axles. Guess which way I went?




Little background info on the truck in question, it is a 99 GMC Yukon grandpa ordered straight from the factory in Oct 1998, fully loaded with all the bells and whistles GMC thought fit for a non-Denali Yukon. Mom inherited it in 2003 when grandpa passed, but they couldn't keep it so my brother bought it. In 2007 he offered it to me for a good price, just before oil prices shot through the roof and fullsize anything became worthless. That was annoying. But for 8 years going, it has been the most reliable and consistent vehicle I've ever owned, and has been more places than most will ever see.


I'm into this "Overlanding" thing, been that way since I was young and dad would take us kids on multi-day camping trips in the family Suburban. My intentions with this build are to that end, making a great, reliable multi-day backcountry off-road explorer. Originally I was going to stickk with IFS for it's highway manners, but my friend Keith can be blamed for going with an SAS. At first, I was going to use a Dana 44, but then Keith intervened and offered me a Dana 60 at the right price, and it snowballed from there... now I have a 14 bff from a 2003 srw one-ton Chevy with a gov-lock and 4.56 gears. Friends don't let friends mess up a solid axle swap...


Enough words, on to pictures:

Photobucket had to ghey it up and charge bazillions to host photos, so these ones are gone. :angry1:
 
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Actually... if I'm honest, this is how it currently looks:


(below) (as of December 2014)



Got in an accident on the interstate just before Christmas, changed lanes to avoid heavy traffic and the lane I merged into was nearly stopped for some reason. Oh well, no big deal, nothing major was damaged and everything that was damaged was going to be replaced soon anyways.


Redneck fix:

(below)

FB_IMG_1506620036741.jpg

FB_IMG_1506620046795.jpg
 
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But thanks to Russel Ziegler, I'll be replacing said bumper with an ARB unit, powdercoated to match the lower body color on my Yukon.
 
:waytogo:

I loves me some gmt400s. Believe me if your friend didnt do it and you came in here with an overland build on ifs for this thing I would have stepped in and done my best to convince you to SAS lol.


So whats the front suspension plans? Radius arms are a good way to go if you're looking to keep comfort and still be easy.
 
I have an ORD SAS kit and a set of Tuff Country EZ ride leaf springs, keeping it simple.

My eventual goal is for about 5" of lift on 34" tires. I know 1 tons are overkill for that size of tire but I want to keep it reliable and daily livable still.

The end goal of this SAS is:

~5" lift
34" all terrains
decent ride
decent flex
increased capability
Thumbs up from those that know what they're looking at :waytogo:
 
The front axle is a Dana 60 from a late 80's Ford pickup (balljoint style) currently with 4.10 gears and open. The rear is a 14bff from an 03 Chevy with factory discs and 4.56 gears and a gov-lock. If anyone has 4.56 gears for a Dana 60 let me know, I'd like them.

The front will have Tuff Country EZ rides (2.5" lift) Ford shock towers and ORD crossover steering. The rear will be an ORD shackle flip kit and maybe the lift block that's in there now, depending on how it sits after the swap is done.

Shocks will be custom made Bilstein units provided by, you guessed it, ORD.

The transfer case is an NP 241 (manual shift) from a 95 Chevy 3/4 ton Suburban for its fixed front yoke and removable rear output, which will be converted to fixed yoke. Driveshafts will likely be Tom Woods. Anything else will come from ORD as available from them.
 
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TC 2.5" lift springs is kinda what you need after the spring swap to get 5" of lift? Is that because of the front spring crossmember?
 
I was going to do a stock spring that would net me about 3" lift, but I'd have very little up travel. Eric convinced me to go with the 2.5" spring so I'd have travel in both directions. But I'll end up a little higher than I really want, but there's not much I can do about that.

The old square body frames were designed to have a bulky axle under the front whereas my ifs isn't so bulky so the frame at the front is straighter with less clearance for an axle, so everything just sits lower than older stuff. Springs net about 2.5" lift over what they're meant for.
 
Right on Riley!

Love the looks of the ARB bumpers....did Russell have a spare one or what?
 
Apparently he's giving me the one from Penny as he's making a new one for it. It's a little beat up but the price is right.
 
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You need to come clean the paint off the axle that you painted. Have to move the spring perches so not sure why you painted it.

Buy the spring perch mounts and put the rear in now and get the swap started.
 
You need to come clean the paint off the axle that you painted. Have to move the spring perches so not sure why you painted it.

Buy the spring perch mounts and put the rear in now and get the swap started.
You know I actually measured the spring perches and they're the right width for my Yukon, 47" center to center. I did decide I want new shock mounts for that rear axle, and I'm not entirely sure why I painted it...

I also ordered up crossover steering from ORD.

Also, I'd love to have it done now, but since it's my daily driver I kinda need to wait, that and I need all the parts too, unless you feel like letting my Yukon sit in Twinky's spot on jackstands for several months
 
The aftermarket springs gonna ride lots nicer too.

Sweet your getting that ARB bumper. That will take an inch of lift out lol.

When the work weekend???? It must needs be I come down for this
 
Eric, Riley doesn't seem to get that it only going to be a weekend. Think he has like month long ideas.

Riley get a tape measure out and do some measuring and figure out how long you rear drive shaft needs to be.

Order it.

get some U-bolts and lets put the rear axle in.
 
Riley my man you me and Keith could bust this out fast. If the axles are ready. I has done this before.
 
I know you think it'll go fast, but I still need to get the shackle flip for the rear, as well as the brake lines and the slip yoke eliminator for the t-case. Then the front springs and spring mounts, and new gears for that axle. And I am not going to run around with 6 lug ifs up front and an 8 lug rear axle. There's no need to do any of it until I can do it all, correctly. Patience my friends.
 

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