Replacing CV shafts with an axle in 01 Yukon

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yukonoffroad27

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Looking for any info or help/knowledge I can get. Looking to build a 2001 GMC Yukon 4x4 into a trail rig, and want to find out how to put an actual axle in the front to replace the GM front driveshafts. I have no idea how to do this, but they say anything is possible, so...
 

Chubbs

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It's called SAS. Solid axle swap. Google it. Very common these days. Several companies make an install kit. Mostly hard core off roaders & experienced DIYers who own just about any tool a pro mechanic would have, along with a welding machine, various grinders, recip saw, I mean you need everything, not to mention a dedicated bank account or credit card. The entire front end is cut off and tossed to the side. Requires not only the axle but a different transfer case, driveshaft, completely new custom suspension and steering linkage. If you have to ask, you don't need to know, as they say.
 
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yukonoffroad27

yukonoffroad27

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It's called SAS. Solid axle swap. Google it. Very common these days. Several companies make an install kit. Mostly hard core off roaders & experienced DIYers who own just about any tool a pro mechanic would have, along with a welding machine, various grinders, recip saw, I mean you need everything, not to mention a dedicated bank account or credit card. The entire front end is cut off and tossed to the side. Requires not only the axle but a different transfer case, driveshaft, completely new custom suspension and steering linkage. If you have to ask, you don't need to know, as they say.
Lol thanks for the reply. I get what your saying. Been doing a lot of research and it would be better in my opinion to just upgrade my front driveshafts and suspension and leave it at that. I don’t even have a shop to work on stuff, cause I’m 16 and still live at home. But someday, maybe I’ll build the ultimate off-road Yukon .
 

Chubbs

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But someday, maybe I’ll build the ultimate off-road Yukon .

You & me both. Don't get anyone pregnant, go to class everyday & study really hard... You might get there someday. You need a high-paying job, minimal expenses and most important .... Don't get put in jail. You should be able to get a good job.

If you are going to try & upgrade your front axles soon to enhance trail-worthiness and have something to brag to your buddies about, you only have 2 choices. There is 1 company that manufactures a high-end replacement and runs like $2000 a set something ridiculous. I looked it up a couple months ago but don't recall the specifics since I cannot buy them.

The other option that is more realistic and feasible: join a few other forums, do some very thorough searching and you will find a couple of guys who fabricate an adapter that you will need to mount 3/4-ton CVs to your 1500 chassis. The 2500/3500 have much larger CV axles and are more than robust for your Yukon. I assume they work with 1500 hubs since I've never seen mention of that little tidbit, but that is something you will need to investigate as the 2500 cv-shaft splines need to match the pattern of the trucks wheel hubs. I would look around for a junkyard/recycler until I find 1 with a 2500 4x4, go ****** the front axles for $40-$50 (if you're ambitious I suppose purchase a brand new set via RockAuto cheap enough) then see if they will work on your wheel hubs and how much, if any lift/height is required to fit the uprated 2500 axle to the 1500 chassis specs. In other words the shafts have to sit flush between the wheels hubs and the differential carrier, just like your original axles; not too tight, not too loose or the "cv" part of the assembly will fail. If the 2500 are longer, you need the aforementioned 'adapter' in place to examine how much distance that piece will take up and should get you close. If the distance is still tight, lifting the truck 1-2 inches should put them just about right since the adapters are most likely engineered with a leveling kit in mind. You will have to converse with the guy who makes them. Have fun and report your finding back to this thread.

Also, any truck worthy of being referred to as "a rig" should have on-board air and even a welder if you are really intelligent. The on-board air is useful from everything to airing your tires back up for public road use after a day of being aired-down on the trails, to running pneumatic tools, cleaning stuff off, blowing up a mattress or what have you. I need 1 for tools and so that I can be mobile as a Wannabe mechanic. If you are clever, you use a big, old YORK a/c from the 70s modified with a bracket to run with your serpentine belt so you don't take away valuable storage space. I think welders are made from old, vintage alternators from back in the day when they used to be stout. Another thing I learned from my Land Rover days is keeping the suspension height minimal while gaining as much ground clearance as possible. People with hordes of cash buy these things called portal axles to achieve such a combination. Look that up 1 day. That's all I have for you, on-board air & portal axles. That's how you start a trail rig or expedition truck.
 
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Chubbs

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@yukonoffroad27

You have a good vehicle for a beginning driver. I was able to do a lot with my trucks in high school just having a part-time job @ the grocery store and hanging around like-minded people with the same hobby and always eager to help. It's almost necessary, being that young, to have friends that like the same thing. This is where you get access to shops, tools, welders, etc.
we were installing our own lift kits and helping one another buy tires & winches way before we had cell phones and debit cards. Good times
 

Chubbs

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That's because they weren't invented yet.:joke:

haha. I'm not that old. my father had 1 of those "Zack Morris" cell phones I used to mess with. I was watching 'SBtB' on Sunday and there it was big as life, back when they were referred to as "mobile phone"

the little Nokia's blew up when I was in college. that is also when people began using debit cards. It was such a hassle having to wait for the mail, take and cash your mother's check at the bank, go back home and give the roommates your rent money.

sorry to hi-jack. I was still thinking about that moe-byle phone.
 
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yukonoffroad27

yukonoffroad27

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You & me both. Don't get anyone pregnant, go to class everyday & study really hard... You might get there someday. You need a high-paying job, minimal expenses and most important .... Don't get put in jail. You should be able to get a good job.

If you are going to try & upgrade your front axles soon to enhance trail-worthiness and have something to brag to your buddies about, you only have 2 choices. There is 1 company that manufactures a high-end replacement and runs like $2000 a set something ridiculous. I looked it up a couple months ago but don't recall the specifics since I cannot buy them.

The other option that is more realistic and feasible: join a few other forums, do some very thorough searching and you will find a couple of guys who fabricate an adapter that you will need to mount 3/4-ton CVs to your 1500 chassis. The 2500/3500 have much larger CV axles and are more than robust for your Yukon. I assume they work with 1500 hubs since I've never seen mention of that little tidbit, but that is something you will need to investigate as the 2500 cv-shaft splines need to match the pattern of the trucks wheel hubs. I would look around for a junkyard/recycler until I find 1 with a 2500 4x4, go ****** the front axles for $40-$50 (if you're ambitious I suppose purchase a brand new set via RockAuto cheap enough) then see if they will work on your wheel hubs and how much, if any lift/height is required to fit the uprated 2500 axle to the 1500 chassis specs. In other words the shafts have to sit flush between the wheels hubs and the differential carrier, just like your original axles; not too tight, not too loose or the "cv" part of the assembly will fail. If the 2500 are longer, you need the aforementioned 'adapter' in place to examine how much distance that piece will take up and should get you close. If the distance is still tight, lifting the truck 1-2 inches should put them just about right since the adapters are most likely engineered with a leveling kit in mind. You will have to converse with the guy who makes them. Have fun and report your finding back to this thread.

Also, any truck worthy of being referred to as "a rig" should have on-board air and even a welder if you are really intelligent. The on-board air is useful from everything to airing your tires back up for public road use after a day of being aired-down on the trails, to running pneumatic tools, cleaning stuff off, blowing up a mattress or what have you. I need 1 for tools and so that I can be mobile as a Wannabe mechanic. If you are clever, you use a big, old YORK a/c from the 70s modified with a bracket to run with your serpentine belt so you don't take away valuable storage space. I think welders are made from old, vintage alternators from back in the day when they used to be stout. Another thing I learned from my Land Rover days is keeping the suspension height minimal while gaining as much ground clearance as possible. People with hordes of cash buy these things called portal axles to achieve such a combination. Look that up 1 day. That's all I have for you, on-board air & portal axles. That's how you start a trail rig or expedition truck.
Thanks for the advice! I am currently single (and probably will be for a long time), and I’m actually taking classes at a local vocational school to get a certification in machine-tool. (Basically to be a machinist)I figure if I ever want to do much off-roading and traveling, I need a good job and minimal reasons to not go lol.

I’m loving the idea of putting 3/4 ton axles on my Yukon, that sounds like a great idea, and I’m gonna try to do it. I know a couple junkyards around here where I can probably find what I need. I’m pretty familiar with stuff like welders and onboard air (from reading to many off road magazines probably) and hopefully someday soon I can get nicer upgrades like those lol. Also have read a little about portal axles. Very cool concept! But like you said, very pricey lol. And for a while this will be a bit of a budget build. I’ll definitely be looking for the parts you mentioned. That seems like the best most cost-effective way to go. Here is my mindset: There are a lot of popular off-road vehicles, (like jeeps) that you see at every off-road park and trail in the country, and they’re good off-road. Plus there is a huge market of parts and upgrades for them. But those are becoming so dominant, you don’t see a lot of variety in vehicles being built for the trails anymore. I like different, and I think building my Yukon into a trail driver would be pretty different, and decently capable. I have a few friends who are pretty good welders, and with my knowledge of fabricating and theirs of welding, I think I can get a lot done. Anyways, I’ll keep you updated, and thanks for the help!
 

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