[jonbest]

So, my wife has a 1989 6.2 liter diesel Suburban that she LOVES. There will be no convincing her to get a Matrix or something else that actually makes sense.

We've gotten 23-24 mpg with it, stock, specifically on three most-of-a-tank 65-70mph highway trips. Generally, though, it dwells in the 18 mpg range.

It needs a torque converter- the one in it has clearly worn itself into high-stall mode. Fortunately, I get to replace the torque converter with virtually no (additional) labor, if you ignore the time and cost of the new engine it needs.

So, since I'll be doing some portion of the work, I'm considering a few different things to do at the same time. I'm looking for feedback and thoughts, specifically for mileage and reliability. The Suburban is half ton, 2wd, 700R4 with overdrive, 3.08 rear gears, stock wheels/tires.

Considering (with varying levels of certainty):
Low stall (~1200) torque converter
Electric fans
Grill block/system, including...
...ram/cold air intake
Exhaust (?)
Synthetic fluids (dif and oil, at least- not sure what the 700R4 would like)

I've got some plans for aero as well. I can't convince her to lose the roof rack, but she hasn't noticed that I removed the crosspieces, and I've conveniently avoided putting the rear spoiler back on after 'accidentally' grabbing it and ripping it off. Although I'll need to replace the duct tape on the holes sometime soon (Kamm mounting points?). But I digress.

What else should I consider when the thing is all in pieces? Any other thoughts/suggestions?

Thank you!

Jon