1994 Diesel Suburban Build

[aardvarcus]

Looking good! I always liked the look of the GMT-400 crew cabs. Spoiler alert- I have the same hubcaps for my Suburban (I am modifying them to work with my GMT-800 16"factory alloy wheels). What size tire did you go with?

[aardvarcus]

So I attached some pictures of my prior work on the radiator, hoses, and coolers mentioned previously.

Last night I started tackling the fuel filtration system while waiting for my oil cooler lines. The basic setup will be a pre-filter, electric fuel pump, and post-filter. This will all fit on the drivers side frame rail, back behind the torsion bar cross-member. (Where the GMT-400 pickup trucks have their fuel tank.) I would have put it all roughly where the stock electric fuel pump was, but the torsion bars were in the way with the filters I am using. I had to fab some brackets which will bolt onto the top of the frame and come out and down to allow the filter housings to bolt on the inside.

[deejaaa]

yours is looking good!
went with 235/85R16LT. found them on craigs.

[aardvarcus]

Got some more progress made in the past few weeks.

Got the oil cooler lines finally run, that one project was a huge time sink as I had to re-evaluate and redo work repeatedly until I got to a functioning solution. Seems that everything that could have gone awry did, but finally now the lines are in, routed, and supported. Ended up with stainless/PTFE (Teflon) and AN fittings.

Got the exhaust pipe installed and welded up, cut a bit off the new and old to get the lengths right and had to weld it up in place as the cross members prevented me from snaking it out after it was tack welded to fully weld, so I did it up under the vehicle.

Got the fuel filters mounted and all the fuel supply and return hoses routed. Got the air conditioning compressor and brackets installed, and the serpentine belt put on. Put a jeep style steering shaft on with double universal joints, in lieu of the stock style with a rag joint on the steering box end. Put the steering column back in the vehicle to be able to steer it back out of the garage.

Anyway, some pictures.

[deejaaa]

that's great progress. i'm going to replace my rag joint also with a jeep type. i got a FEA yesterday and they said it was sloppy. i had to buy new tires last week.
they will also replace the hydrobooster next week because it's leaking.

[aardvarcus]

Progress on this project stalled a bit due to other priorities and bad weather (with the vehicle back outside), but I have been able to wire wheel and re-prime some corrosion spots on the inside floor where some water had sat under the carpet. Also found the two offending leaks, one was due to the rear weather-stripping shrinking slightly, I cut it on the bottom to allow it to shrink/expand a bit so I could get it to re-seat fully on the metal lip it rides on. All the side doors had a cut on the bottom, only the rear was one complete loop, and it pulled away from the corners and let some water inside. The other leak was due to the caulk between the rear door and the back window at the top next to the roof cracking. I temporarily just went over this with some other sealant; I will do a more permanent fix later.

I have gone round and round redesigning the electrical system, but I have started making brackets to mount the new fuse boxes up under the middle row driver seat. I hope to get enough of the electrical system made up to be able to start and run the engine soon.

[aardvarcus]

I have gotten a bit done on a few evenings here and there. I got my bracket made, all the components mounted, and the penetrations and grommets installed to put the new electrical system under the driver’s side middle row seat, I have about 5” of space there which should be just enough to get everything to fit. The fold up action provides easy access for fuse or relay changes, and the entire system is designed to be removable thanks to quick disconnect plugs should the overall system need changed or repaired. I will end up putting an additional cover over the device under the seat to protect it further. Anyway some pictures.

[aardvarcus]

After a two month hiatus outside with limited progress, the patient got wheeled back into the operating room last night. The immediate plan is to put in all the fluids and hook up enough of the wiring and odds and ends to be able to start and drive the vehicle around the driveway. After that the focus will be getting the remainder of the wiring, interior, and accessories completed to get it on the road.

[ctmaybury@yahoo.com]

Subscribed. Nice build. My 97 5.7 gasser auto stock could top 18 mpg highway. With the na 6.5 and the 5sp manual, I bet you'll hit 30mpg without aero mods. Can't wait to see it run.

[ctmaybury@yahoo.com]

Did you address the 5th gear nut issue with the nv4500 before install? I had that tranny in my 95 chevy 2500 with no issues. In my 98 dodge 2500, a nut came loose and I lost 5h gear. No damage to the internals. The fix is simple and cheap, but easier with the tranny out. I don't know if they stake the threads., use locktight or use a nylock nut. Mine let loose when I was on a trip pulling my travel trailer, so I had a shop fix it. Someone on cumminsforum said it was vibrations from a diesel chugging along at low rpm that cause it to loosen. I drive like that often, and it sounds like you will too. Otherwise it is a great tranny tough enough for hard service.

I can't wait to see mpg numbers. I've only had gassers in my many gm trucks over the years, but am sold on diesels now. A friend had the 6.5 na in a pu and got fantastic mileage.

I hope you get a chance to work on the truck soon. I want to hear more about the mechanical injection pump. I have 2 24v dodges with the cummins 5.9, and on one of them I got rid of all computer control on the engine. It simplifies everything.