Just Fishing's 09 Tahoe Build thread

[Just Fishing]

Got a bright idea while i wait for more parts.

Took some more scrap 2x4's and cut off a few decent pieces to see if I could clearance the thicker area on the 4-5-6 input shaft.
Then took my little setup and screwed it onto a table that I luckily didn't throw out yet to offset it for the shaft to clearance.

Will it work?

Answer = yes


So, I have the 4-5-6/input ready for upgrades later this week.

 

[swathdiver]

Can't remember, is this a RWD or 4x4 truck?

 

[Just Fishing]

Can't remember, is this a RWD or 4x4 truck?

4x4

 

[Just Fishing]

And mail woman delivered some packages today.
It appears I have all of my transmission parts and my rods.



It's going to be a party this weekend!!

 

[Just Fishing]

I didn't get a picture of it yet, but I took my transfer case and taped up the shaft ends, and the breather.

then rolled it out front, hosed down with the finest engine degreaser, and used a toothbrush to get all of the crud off of it.
Paying special attention to bolts, and the electrics.
I haven't decided if I'm going to crack it open and freshen it up or not, but this would be a good start.

At a minimum, it will let me see if there is a leak somewhere.

Most likely I'm going to run it as is.
Main thing I would like to do would be to clean the pump pickup, and reseal it...

I'm planning to reinstall the transfer case with the transmission, with the engine out it's easy enough to roll it under there and slide it back into place...
4x4... pita but I need it.

 

[pwtr02ss]

I didn't get a picture of it yet, but I took my transfer case and taped up the shaft ends, and the breather.

then rolled it out front, hosed down with the finest engine degreaser, and used a toothbrush to get all of the crud off of it.
Paying special attention to bolts, and the electrics.
I haven't decided if I'm going to crack it open and freshen it up or not, but this would be a good start.

At a minimum, it will let me see if there is a leak somewhere.

Most likely I'm going to run it as is.
Main thing I would like to do would be to clean the pump pickup, and reseal it...

I'm planning to reinstall the transfer case with the transmission, with the engine out it's easy enough to roll it under there and slide it back into place...
4x4... pita but I need it.

I sat my trans and transfer case up in there first, then put the engine in. Made it easier on the avalanche because it has a crossmember welded across the frame that won't allow the transfer case to drop strait down. It hits the engine in the front and the crossmember in the back.

 

[Just Fishing]

I sat my trans and transfer case up in there first, then put the engine in. Made it easier on the avalanche because it has a crossmember welded across the frame that won't allow the transfer case to drop strait down. It hits the engine in the front and the crossmember in the back.

Yeah, I was wondering how the hell to do that.
that same crossmember is on my tahoe.

I ended up removing my sway bar, then rolled the entire assembly forward until it cleared.

but with the engine in place, that's not an option.

Some videos I watched on the subject made the tcase look so light.
But I am pretty out of shape.

Probably would have been easier if I had an actual transmission jack.

 

[pwtr02ss]

Yeah, I was wondering how the hell to do that.
that same crossmember is on my tahoe.

I ended up removing my sway bar, then rolled the entire assembly forward until it cleared.

but with the engine in place, that's not an option.

Some videos I watched on the subject made the tcase look so light.
But I am pretty out of shape.

Probably would have been easier if I had an actual transmission jack.

Yeah, I just slid the whole assembly forward to get it passed the crossmember and went up and back. The bellhousing rested on the sway bar

 

[Just Fishing]

Well wife woke me up nice and early today, so I decided wth.
Started on bushings!!

My cheap amazon 52-piece bushing tool worked fantastic.
You can stack the drivers to make your own stepped driver.
Some of the inner pieces didn't quite fit tightly, so i used a little electrical tape to fill in the void for a nice tight holder.

Everyone that I did that with went in absolutely perfect.
Ones that I didn't quite have enough space for that, went in a little tight.

One of the bushings was tighter than i wanted, so it turned into some careful lapping using some car polish.
Internet says to sand.

So, I spent some time this morning until it spun pretty free
Nice solid seal... lol

for recessed bushings, I took pictures of the recess and then used my dial caliper to measure how far down the bushing was sitting.
then drove the bushings in after.

anyways, I got the clutches and pistons all installed, and air check pass.
Next up is the rear carrier cleanup and bushing replacement.

from there, I start assembling!

 

[Just Fishing]

Oh yeah, precision youtube videos.
One of them he called out the rear case bushing.
Saying you need to line up the "lube hole" in the bushing with the space in the case.

I did some research after noticing my OEM installed bushing did not line up with that hole.

What i found out is that pass through hole is just to allow fluid to escape back into the transmission and not cause a leak of the rear seal.

Lube is controlled by the rear carrier, there is a lube hole that comes from the shaft to lube up that bushing.
Lining up that hole will let the pressurized oil to leak right through it.

Do not line up the hole.

I put my little hole exactly where the original bushing was.