strutaeng's 04 2500 4x4 project Suburban

[strutaeng]

Well Saturday my oldest daughter had a championship M.S. varsity volleyball game. Unfortunately, they lost. Got home and they had 50% chance of rain, so all I did was wash and held off masking. I did an engine oil change instead. The drain bolt was super clean. Of course, it didn't rain on Saturday after all, LoL. But Sunday we got a downpour.

Tonight I dropped the transmission oil pan. I started loosening the bolts and ATF started dripping everywhere. This pan doesn't have a drain bolt. I grabbed a drill and drilled a small hole where the drain bolt would go (I have another drain pan with the drain bolt laying around to swap.) Kinda of a pain actually to remove though. I realized towards the end the crossmember has these holes to slide a 1/4" ratchet and put a socket at the other end to remove the rearmost bolts.

 

[strutaeng]

Got the other transmission pan reinstalled. I couldn't get the rearmost pan bolt: tried and tried and finally gave up. I removed the crossmember.

I drilled some 'ol holes and cut some reliefs on the transmission mount. Hopefully next time I replace the transmission fluid this would be a bit easier.

I just drained the transfer case and this is what came out. It looks and smells like ATF. I believe this transfer case requires some blue-looking fluid. I already dumped it, but that only looked like 1/2 quart. :-(

 

[Fless]

If it's an NP8 RPO NP246 two-speed case it takes just short of 2 quarts of Auto Trak II (yes, it's blue).

 

[strutaeng]

If it's an NP8 RPO NP246 two-speed case it takes just short of 2 quarts of Auto Trak II (yes, it's blue).

I'll double check the RPO code on the glovebox, but I'm pretty these SUVs were only offered with that transfer case. It has the round pushbutton with "Auto."

 

[Fless]

There should be a round badge bolted to the case unless it's been removed.

EDIT: I'll bet the TC is ruined if they used tranny fluid in it; might need a rebuild.

 

[strutaeng]

There should be a round badge bolted to the case unless it's been removed.

EDIT: I'll bet the TC is ruined if they used tranny fluid in it; might need a rebuild.

Umm. When I bought the truck the owner's son told me it was stuck on 2Lo and that's how they had been driving it.

I checked underneath and wiring harness to the transfer case motor was severed. I respliced everything but still nothing. Then I replaced the little reluctor wheel on the motor (I can't remember what the part is actually called.) That fixed the problem. TC works from 4LO, 4HI, and the Auto function. I confirmed by jacking the rear end on the air and I was able to pull forward.

I just drained the fluid from the pan and didn't find any glitter or clutch material. My understanding is that the NP246 uses some clutches similar to a transmission (actually shares the clutches with some Dodge transmission?) This is my old transmission pan where I drilled a hole, hence the duct tape. LoL

I guess I need to figure out what to do now? For sure I'll be at least replacing the correct TC fluid.

 

[strutaeng]

Also, my Dad and brother were here to morning. My Dad's OBS truck had the fuel level sender go out so they needed my engine hoist to lift the bed.

Anyways, I had them help me install the hood. The color looks like a pretty good match. The only thing is on one side the hood is bent a bit and I didn't realize it. Oh well, probably happened from it leaning against my shed for several years. I'll order a bug flector and it should be fine.

It was super windy today so I didn't even try to paint the roof. And we are supposed to get a cold front later this week. Doh!

 

[nsogiba]

Hope the transfer case holds together! Glad you caught the fluid issue.

And yes, that rear trans pan bolt or two are a total nightmare to get to. I was able to snug them up with a combination wrench but no way was a torque wrench and socket going to fit.

Paint match looks great!

 

[strutaeng]

I ordered the blue fluid. Should be here on Friday. I'll do the front differential next. I watched a video and it looks pretty easy.

I've got a 14 bolt 10.5" 4.10/G80 I had bought to swap into my OBS, but I think I'm going to swap into this truck, since it's literally a direct swap. These 6.0 have the 14 bolt 9.5". Mine also happens to to be 4.10 ratio.

I think I'll attack the headliner next. I've never done that job and it actually looks like a bear. I'm thinking I'm going to cut the wiring and install quick connects to avoid getting into the lower wiring harnesses. I've got a gun with the 1.7 and 1.9 mm needles, so I think I'm good there.

My brother pointed out that I should consider ordering the darker gray headliner to match the pillars (I had not realized that the headliner is actually a lighter color than the pillars until he pointed that out.) TBH, I've never been a fan of the 2-tone interior. The first time I saw it when I bought these suburbans 4 years ago, I thought someone had swapped interiors and was mismatched, LoL.

I think it's the "smoke" color the one that matches the darker gray, no?

2000 - 2006 Chevrolet Suburban | Headliner Fabric Replacement Kit

3/16" Thick / 60" Wide - Foam Backed Headliner Fabric Roll Length will be cut to fit: Chevrolet Suburban (2000, 2001, 2002, 2003, 2004, 2005, 2006) Please select the applicable color and fabric length options for your vehicle. Selecting to add fabric for the sunroof sha

www.moonautotops.com

 

[strutaeng]

Hope the transfer case holds together! Glad you caught the fluid issue.

And yes, that rear trans pan bolt or two are a total nightmare to get to. I was able to snug them up with a combination wrench but no way was a torque wrench and socket going to fit.

Paint match looks great!

Thank you! Definitely a good learning curve to do automotive refinishing. But everyone has to start somewhere, right?