Rocket Man's 02 Denali Build Thread AKA "THE BEAST"

[George B]

This is why I hate waiting for parts. Because now, to be honest, I’m not even returning the rear evaporator. Here’s my thoughts: I hate having something in any of my vehicles that doesn’t work. The rear ac hasn’t worked for awhile, I don’t believe. I think I quit trying to use it because it blew warm air. Maybe that was the blend door actuator, maybe it was the evaporator. IDK. I don’t really know, and don’t remember when it stopped working. I think I’ll end up fixing it. I did find the line kit on Amazon and in fact came super close to buying one, because it was one day delivery and I could still wrap this thing up this weekend BUT I discovered that was for the XL. The one for the short wheelbase is actually only available on eBay or Amazon non-Prime for around $400 shipped, and about a week out. So….I’m gonna get this put back together with the block off kit. Then I’ll most likely buy the hose kit and fix the rear ac. My buddy will only charge me once, and only $60, to evacuate and recharge the system. There’s still a bit of hot weather left this year. Or I might wait until next year. The hose kit is on my Amazon list. I blame @George B for this latest nonsense. Thanks George!

Glad I could help!

But seriously, you are so thorough I figured you would come to this in the long run anyway.

 

[89Suburban]

This is why I hate waiting for parts. Because now, to be honest, I’m not even returning the rear evaporator. Here’s my thoughts: I hate having something in any of my vehicles that doesn’t work. The rear ac hasn’t worked for awhile, I don’t believe. I think I quit trying to use it because it blew warm air. Maybe that was the blend door actuator, maybe it was the evaporator. IDK. I don’t really know, and don’t remember when it stopped working. I think I’ll end up fixing it. I did find the line kit on Amazon and in fact came super close to buying one, because it was one day delivery and I could still wrap this thing up this weekend BUT I discovered that was for the XL. The one for the short wheelbase is actually only available on eBay or Amazon non-Prime for around $400 shipped, and about a week out. So….I’m gonna get this put back together with the block off kit. Then I’ll most likely buy the hose kit and fix the rear ac. My buddy will only charge me once, and only $60, to evacuate and recharge the system. There’s still a bit of hot weather left this year. Or I might wait until next year. The hose kit is on my Amazon list. I blame @George B for this latest nonsense. Thanks George!

I totally get how you feel about the rear delete. But it is also not in your nature to do things half assed either. I was waiting for this change of heart lol. But either way I support you. Learning a great deal here thanks to your efforts. Please keep us updated on the step by steps for the rest of us DIY'rs. $60 bucks is a good deal. I have gauges and access to a vacuum pump from work if I need it. Not sure if I want to drop coin on a vacuum pump. On my old trucks I used the vacuum of the engine to draw it down best I could back in the day.

 

[Rocket Man]

I was just now thinking of what else I need to get the rear done. I’m sure those quick connects on the heater hoses will break. Anybody done these? I’m wondering if I just need to cut the ends off the hoses and use clamps onto new quick connects?

Also looking at the expansion valve, need to order one of those. I see why I couldn’t flush the rear evaporator out once I looked at the new one and the fact this valve is there, if it’s normally closed. I looked up how an expansion valve works in an ac system and all that did was make my eyes glaze over and put me into a catatonic state. I swear this shit is like rocket science to me. Atomizing particles and shit like that. I’ll just order a new one, it’s like 16 bux unless I was dumb enough to buy the ACDelco which is 50. The Denso is probably the same part anyway, they make the OEM compressor. Maybe a bad valve is why the rear wasn’t working.

 

[Rocket Man]

I totally get how you feel about the rear delete. But it is also not in your nature to do things half assed either. I was waiting for this change of heart lol. But either way I support you. Learning a great deal here thanks to your efforts. Please keep us updated on the step by steps for the rest of us DIY'rs. $60 bucks is a good deal. I have gauges and access to a vacuum pump from work if I need it. Not sure if I want to drop coin on a vacuum pump. On my old trucks I used the vacuum of the engine to draw it down best I could back in the day.

You’re right I hate doing things half assed. I just want my truck back on the road and once I figured how to do that and then add the rear project after I was ok. If I would have known at the start I needed these extra parts and then ordered them I would have never even had second thoughts but I was already almost a week in after ordering the flush kit and then finding out I couldn’t flush the rear and then finding out I couldn’t disassemble the damn thing to flush it either. The thought of it sitting another week waiting on those rear lines made me think about the delete. So now it will just be a temporary delete. I mean, driving The Machine isn’t terrible but it’s also not the rig to just jump in and quickly run somewhere. I need my daily back. I had to go to my dermatologist yesterday and I was stressing about it being in their parking lot while I was in there. It’s a terrible parking lot and there’s a lot of old people going there.

 

[Tonyv__]

I was just now thinking of what else I need to get the rear done. I’m sure those quick connects on the heater hoses will break. Anybody done these? I’m wondering if I just need to cut the ends off the hoses and use clamps onto new quick connects?

Also looking at the expansion valve, need to order one of those. I see why I couldn’t flush the rear evaporator out once I looked at the new one and the fact this valve is there, if it’s normally closed. I looked up how an expansion valve works in an ac system and all that did was make my eyes glaze over and put me into a catatonic state. I swear this shit is like rocket science to me. Atomizing particles and shit like that. I’ll just order a new one, it’s like 16 bux unless I was dumb enough to buy the ACDelco which is 50. The Denso is probably the same part anyway, they make the OEM compressor. Maybe a bad valve is why the rear wasn’t working.

If I’m not mistaken my buddies avalanche had broken quick connects on the heater core at the firewall. He just cut the quick connects off and slipped the hoses on with hose clamps. Has had heat ever since.

Now I know you don’t like to half ass but what’s the difference between hose clamping to the quick disconnect or just hose clamping to the heater core nipple directly

 

[Rocket Man]

If I’m not mistaken my buddies avalanche had broken quick connects on the heater core at the firewall. He just cut the quick connects off and slipped the hoses on with hose clamps. Has had heat ever since.

Now I know you don’t like to half ass but what’s the difference between hose clamping to the quick disconnect or just hose clamping to the heater core nipple directly

The ones in the rear are 90* elbows, not sure if I can connect straight on. Might not be enough hose. Looks like there’s room though.
Disregard the vise grips and failed attempt at removing that ac line.

 

[Tonyv__]

The ones in the rear are 90* elbows, not sure if I can connect straight on. Might not be enough hose. Looks like there’s room though.
Disregard the vise grips and failed attempt at removing that ac line.
View attachment 378983

Ohhhh I didn’t realize you were talking about rear heat… I didn’t have that luxury in my Tahoe lol. I don’t understand why I had air only in the rear

It was nice to have the breeze on the back of my neck in the middle of the summer. But the winters were cold. Took a while to warm that truck up

 

[RAMurphy]

Based on the pain you are going through I'm glad I did not have the same issue. Although if I did, I might of been able to provide a few pointers.

 

[Rocket Man]

Thinking about those rear quick connects made it impossible to not think about the fronts. For the last couple of years I have put off replacing the quick connect T’s at the firewall. Since the blower is right there it seemed like it would be impossible to do without removing it which is a two day job. It got to be one of those things I tried not to think about. But now I have the accumulator out, the inner fender out…so last night I decided I wasn’t going to be skeered anymore. And this morning I attacked those things. They wouldn’t be so bad if they weren’t so hard to get to. But accessing them from the wheel well, from under, made it doable. Still real hard but with enough cutting and breaking them, they’re off. I don’t think there’s any way for me to do the Gruven fix with all the clamps due to the blower so it’s good that I’m ok with the OEM parts. I have had them in my parts drawer. I also had an elbow and clamps in my glovebox in case the t’s ever broke. Mine were definitely brittle and ready to break but they ARE 21 years old. If the new ones last half that long it will be fine. I have the Dorman heater hose ordered, the one with the metal Y. Supposed to be here tomorrow.

And I ordered the rear AC hose kit. It’s only money, right? Not like I haven’t dropped a few dimes on this truck. It actually already shipped. I’ll see how it goes, I might just do everything and then recharge the system. I have another truck to drive after all.

 

[RAMurphy]

Great, another project for me. Mine have been on for her entire life too. Do you have the part numbers?