2002 Yukon, 140k miles, Fixing up over time

[tgui]

I got pissed off this winter dealing with snow. I drive a 420hp RWD Lexus ISF. Even with snow tires this thing is horrid in snow. God forbid I try to drive over a mound of the white stuff.

So I got this Yukon as a hobby and a solution to next winter. 2002 Yukon STL, 140k miles for $3700. I bought it from a BMW dealer that was about to ship it to an auction. It would not pass inspection as the suspension, brakes, tires, parking brake, seals... and many other things were simply crap. Engine and trans seemed ok. Similar Yukons here in better repair were about $6500, so I figured I have $3000 for parts and will end up with something I can trust and better yet know how to fix!

Body and interior are pretty good.



My car wrenching has been limited to 6 years ownership of a highly modified Subaru WRX STi. This Yukon is a whole new ball game. This sums up how I feel at times:


I have to buy a ton of larger tools.

First major issue was the passenger front axle seal flinging oil everywhere. What a mess. I had to pull off part of the front diff to replace the seal. I learned about anaerobic sealant.

Out with dirt in it. I should have cleaned the underside better. Ohh well.


Bad seal. Got a Timkin replacement from the 'zone.


Back together ready to be put back in after some gasket cleanup.


plenty more to come......

---------- Post added at 12:53 PM ---------- Previous post was at 12:48 PM ----------

Front rotors were toast. Pads worn. Calipers stuck. Did a rebuild with new parts.



---------- Post added at 01:00 PM ---------- Previous post was at 12:53 PM ----------

I thought I could squeak by inspection.

Nope. Stupid me I didn't realize the parking brake didn't work very well. So I tore into the passenger side and this is what I found:


Nothing. Everything removed. Are you kidding me?!


Turns out after getting all new parts that the screw hole to mount the brake shoes was filled with a snapped off screw from the prev owner. This is why all hardware was removed. Good god.

So I fixed everything.

 

[NathanJax]

Looks like your having some fun!!!

 

[jomulk56]

Nice work. Will you come fix my parking brake? I have zero ambition to dig into it any time soon.

 

[coolchuck]

Welcome. Thats a some good work going on. This is a great place for info if you get stuck on a project.

 

[tgui]

So part of the brake work was replacing the dust shield. I tore that piece of junk off.




But all for naught since to get that rear knuckle off, I had to take the rear axle off.. which meant I had to take the rear diff cover off to pull some pins out.. which means new gasket and new fluid. Soooo no wonder the prev owner said forget it.

Here is my G80 locking diff time bomb!

How can I tell if this sucker still works?


---------- Post added at 09:19 PM ---------- Previous post was at 09:15 PM ----------

Nice work. Will you come fix my parking brake? I have zero ambition to dig into it any time soon.

Ha! Sure drive over to VA.

Its actually pretty easy work. Whats wrong with yours?

---------- Post added at 09:31 PM ---------- Previous post was at 09:19 PM ----------

Oh and finished the drivers side. Lower/upper control arm, sway bar link, shock. Waiting for Amazon to get me the passenger side parts. I used Raybestos arms, moog link and Bilstein shocks.

The Raybestos ball joints were damn tight and didnt take much grease. I pumped hard and none came out of the boot. Once grease was in they moved nicely.



Oh and get a real tool to remove the torsion bars. Worth it.

 

[jomulk56]

Ha! Sure drive over to VA.

Its actually pretty easy work. Whats wrong with yours?

It's not engaging and just needs replaced when I do the brakes. You're doing some major work. All looks good tho man.

 

[tgui]

It's not engaging and just needs replaced when I do the brakes. You're doing some major work. All looks good tho man.

I hear ya and thanks for the compliments. I literally have not done work like this on a car/truck ever. My prev experience was tuning, turbos, injectors etc, not so much suspension and manly parts.

Oh, hint. I'll be turboing this truck.

---------- Post added at 05:42 PM ---------- Previous post was at 05:39 PM ----------

And here is how you test a G80 to see if its still working. I'll do this when I slap in the new rear shocks.

https://www.youtube.com/watch?v=xCwcr7Sj7Hw

 

[OHSIXX]

Welcome.....DO WORK

Looking good so far.......

 

[tgui]

I'm an engineer and run the engineering at a software company. I'm so **** I poop only equilength turds ordered by color and fiber level. So I made a list of work done.

Yuuuuuup! Chuck Testa!

Work Completed
3/22/2014	Engine Oil
	Air filter
	Front Rotors
	Front Calipers
	Front Pads
	Front diff pass axel shaft seal
	Front diff oil
	
	
3/29/2014	
        driver rear knuckle
	driver rear dust shield
	driver rear parking brake shoe & other hardware, full rebuild
	rear diff fluid change
	rear diff new gasket
	
	
4/5/2014	
        driver side done
	lower/upper control arm
	sway bar link
	bilstein shock
	
	
4/7/2014	
        belt
	spark plugs
	spark plug wires
	
	
4/9/2014	
        rear shocks, bilstein
	rear wiper clogged, fixed
	rear wiper stuck, fixed
	fuel filter changed
	
	
4/10/2014	
        passenger side done
	lower/upper control arm
	sway bar link
	bilstein shock
	
	
4/11/2014	
        michelin ltx ms/2 tires installed, 70k mile warranty
	alignment, needs to be fixed, pull to right
	extra key made with FOB

So you wanna remove the fuel filter of a 2002 or earlier truck. Get this OTC tool not the Autobros POS tool. This works. My hands look old.


Here is my rear axel.


The tires, they're round.


ISF with truck.


My floor used to be pristine.

 

[jomulk56]

Looks like you have hieroglyphs on your wall too.


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