Yukon Down, AWD delete, headers, converter etc... - MudInMyBlood Forums
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post #1 of 14 Old 05-29-2016, 03:06 PM Thread Starter
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Yukon Down, AWD delete, headers, converter etc...

So here she is, 2004 Yukon XL, family hauler, Camaro hauler, been my daily driver for the last two years.

I want something that can tow my car with ease, tow other stuff, and generally be usefull. I already have a good tune, efan conversion, and cold air intake.

I figured this conversion may take a while so I bought another daily driver to cover me while the yukon was down.

I figured, I could get a little performance by deleting awd, and by selling the components could offset the price. Once I assembled all the parts, I jacked her up.

First things first we must remove all awd components....this is the non-electronic transfer case. It splits power 70/30 rear/front at all times.

And it weighs about 70lbs.

4wd 4l60e. Looks to be original.

Here's the stock setup.


---------- Post added at 04:05 PM ---------- Previous post was at 04:04 PM ----------

The stock torque converter.

And it weighs about 52lbs.

Front diff about 80lbs.

Front axles.

Lot's of room under here now.


Lots of people say/think you cannot run a 4wd/awd hub on a 2wd truck. They say if the axle is not there clamping it together the hub will fall apart. After inspection it appears that what the axle clamps in the front and rear is the same solid piece, meaning it cannot come apart.


Also if you notice by looking at the axle end there is no abs, meaning everything will function normally with it removed. The abs is in the hub itself.

I also thought this truck had a bad head gasket. Looky looky, a certain stain going down the cylinder head of a leaky steam port. Winning!!!

Some goodies, a built 2wd 4l60e from my buddy Tim Frost @ Pro1 Transmission in Texarkana.

And this pretty thing right here. Its a 2800/3k unit from Circle D.



Smaller then stock.


---------- Post added at 04:06 PM ---------- Previous post was at 04:05 PM ----------

Lighter then stock.

Not gonna hunt down a 2wd crossmember, so I made my 4wd work. The 2wd trans sits about 3 inches higher so I made a small bracket and welded it to the 4wd crossmember.

So here it is mounted up, using a $10 2wd Anchor mount.



The last piece of the 2wd puzzle. An aluminum shaft, 4 inch, .125 wall and 69 3/8th" center to center. I bought this from a driveshaft place in California but you can get a used one off a 2wd version off a wrecked truck, but beware they are hard to come by. Can for size reference.

Another little treat. These are 1 3/4 from Speed engineering. Fit was ok, nothing to get upset about...I did clearance them a bit to get the clearance I wanted.

Trying to get headers on by yourself isnt fun. I made two studs, inserted them so the headers and gaskets had something to hang on. I used the wire to hold the collectors up. I went with GM MLS gaskets to seal em up.

Here's a picture of the muffler and merge. Dynomax bullet and Magnaflow merge. I had it on the truck before and it sounded loud but with a nice tone.

Now that she's back on the ground and running I will give some driving impressions. The converter foot breaks to 26/2800 and flashes from a stop to 3k. To get moving you spin about 2k rpms. The converter feels nice and pulls good on the top end. The headers perked up the midrange and you can especially feel it over 4k, where the stock setup seemed flat and out of steam. And no my front tires didnt fall off even though the internet said they would! I will be pulling the intake soon and fixing the coolant leak and freshening up the top end.

---------- Post added at 04:06 PM ---------- Previous post was at 04:06 PM ----------

Wanted to give this thread an update....I needed to fix the leaking coolant from the crossover line. So I jumped into intake gaskets and whatnot also. Here it is, cold air, efans, and stock otherwise. Also removed the wide Denali engine cover. I dont like everything covered up.



This thing is filthy. Its not so much a leak as it is just weeping from all the seals just a tiny bit over a 200k mile course.



Got the intake removed in about a hour, pretty simple stuff.



A little purple power and elbow grease goes long way.



Showing my fbody roots, I decided to do a throttle body coolant bypass, I had this brass barb in the tool box so I plugged it into the line going to the throttle body. Here you can also see the valve covers which I spent about an hour cleaning.



Since these trucks are known for having rear knock sensor issues due to moisture I decided to do a new ac delco rear sensor, new Dorman harness, valve cover gaskets, intake gaskets just to kind of freshen things up. My stock sensor appeared fine.



We had some kinda crappy weather, but I caught this guy hanging out behind the shop for about half an hour.



On order from Jegs, to quiet things down some. I am gonna install it inline with the bullet muffler.



And a couple of random pics, this is a 4wd/awd transmission mount.



Manifolds.



Front drive axles.



Stock down pipes with Magnaflow cats.


06 Foreman 500 - 29.5 OG Outlaws, 35%, Warn 2.5k, HL^2", <2.5">, EPI, HMF
95 Fourtrax 300 - 27" Zillas, SS212s , Viper 3k, HL^2"
04 XR80 - Stock
07CRF50 - Stock
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post #2 of 14 Old 05-31-2016, 07:42 AM
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did it have the 5.3 in it or the 6?

I just bought an '09 Tahoe with the 5.3 and she feels like she needs to be woken up a little bit. Wondering if a hypertech will do the job. And maybe a magnaflow.


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post #3 of 14 Old 05-31-2016, 08:14 AM Thread Starter
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All Denalis got the 6.0 LQ4 engine. A proper tune (with a laptop tuning software) helps out a bunch plus makes the trans feel so confident. I never liked stock tuning on 4l60es, they always feel kinda clumsy. Yours may have the 6 speed though being its so new. Ive heard those are better.

06 Foreman 500 - 29.5 OG Outlaws, 35%, Warn 2.5k, HL^2", <2.5">, EPI, HMF
95 Fourtrax 300 - 27" Zillas, SS212s , Viper 3k, HL^2"
04 XR80 - Stock
07CRF50 - Stock
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post #4 of 14 Old 05-31-2016, 09:25 AM
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Sounds like (and looks like from the photos) you really know your stuff. That's why I asked lol. I've wanted a Tahoe for a long time, finally found a decent deal on one.


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post #5 of 14 Old 05-31-2016, 10:39 AM Thread Starter
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My buddy bought one for his wife, a newer one like yours. Its nice. They made some improvements over this generation I think. Its all about budget for me, this was a cash truck I bought, so I bought what I could afford. Id like to have a newer generation maybe next go round as the prices continue to fall some.

06 Foreman 500 - 29.5 OG Outlaws, 35%, Warn 2.5k, HL^2", <2.5">, EPI, HMF
95 Fourtrax 300 - 27" Zillas, SS212s , Viper 3k, HL^2"
04 XR80 - Stock
07CRF50 - Stock
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post #6 of 14 Old 06-12-2016, 09:58 AM Thread Starter
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So I had some transmission issues. I appears through my heavy foot I just broke the d.a.m.n. thing. I took it to the builder last week and he said the forward sprag was completely trashed. But, its fixed and ready to come home. Time to make the 180 mile round trip....which goes really fast when you're on a nice new highway.



Pro1 Transmission in Texarkana AR. These guys know their stuff.



After I chatted with the owner for a bit and loaded up it was time to head back home.



I took the stock truck pan off.



And I tried to install a new aluminum pan.......but it wont fit. It seems to be hitting the filter inside the pan.



The filter support risers are obviously made for a car filter (shorter) and this has a truck filter installed. I measured the gap at the pan rail to be around 5/8 from seating on the trans...... and I don't have a car filter, so I cut the **** things off.



Here is a pan depth measurement. Stock truck pan was 3 inches deep, and also you can see the risers after cutting 5/8ths off them.



Success!



Ready to slide back in. The trans jack makes the job easy when you're a one man band.



Walmart no longer carries transmission fluid....dipshits, so I bought a case of this from the local auto parts store....and the price was actually really good.



The new muffler.



No performance loss here.



I added it into the rear section of the pipe but left the bullet muffler also.



Back on the ground and needing a bath bad.



Cheers, you earned it!


So the trans is back to acting right, the exhaust is nice. My impressions of the new muffler is it obviously toned it down. It is mellow and very deep at idle, it has more tone/sound now then it did before. Cruising at light throttle its actually very quiet (you can't hear it inside the truck), under moderate throttle or rpm it wakes right up and lets you know its there. Under full throttle its pretty loud, and the tone breaks up some at mid rpms (kind of what comes with a loud exhaust) but its controlled and not terrible sounding like it was with just the bullet muffler.

06 Foreman 500 - 29.5 OG Outlaws, 35%, Warn 2.5k, HL^2", <2.5">, EPI, HMF
95 Fourtrax 300 - 27" Zillas, SS212s , Viper 3k, HL^2"
04 XR80 - Stock
07CRF50 - Stock
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post #7 of 14 Old 06-26-2016, 10:44 PM Thread Starter
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So basically issue after issue. This transmission has been pissing fluid out about every other drive, its been driving me nuts. I went through two new pan gaskets before I realized it was actually the electrical connector, it was pushed into the case and not sealing. I was able to pull it up and make it click in place. Its also had a funky miss going on and has been down on power. So I ordered up some stuff.

DJM 2/3 inch lowering kit from NorCalSS, and a set of MSD plug and copper NGK plugs from SDPC.



The plugs and wires did fix the miss, and the lowering kit was pretty straightforward. Here is the stock spring vs the DJM spring for the rear.



Here is some after pics, and my impressions of the ride are slightly firmer then stock in the front, and slightly bouncy in the rear. I've ordered the shock relo brackets for the rear to try to help control the rear end movement. I trimmed all 4 bumpstops also.





Remember that daily driver I bought, well the friggen AC decided to act up. So here is another delay in the project. Had to remove the front clip to swap compressors.



Decided while I had it apart to swap the trans filter, which is buried behind the front bumper.

[URL=http://s275.photobucket.com/user/01ssreda4/media/Yukon%20XL/20160620_134757_zpsyqqqfw6s.jpg.html][IMG]http://i275.photobucket.com/albums/jj294/01ssreda4/Yukon

---------- Post added at 11:44 PM ---------- Previous post was at 11:43 PM ----------

I also found one of the radiator fans completely broken off the shroud and unplugged. So, I setup the soldering gun in hopes of making a fast/cheap repair.



Every single finger was broken, but I was able to re-fit them in place, then smear the plastic back together with the tip of the gun. After I was through i grabbed the fan and picked up the whole radiator. I think that will hold. Here you can see a repaired one on the right, and the broken ones around the left side.



Yeah buddy that's the ticket.



Hard work done, so its break time. Nothing like a good airsoft war down the neighborhood street on a hot summer day.



Time to relax with some LSX buddies and fix some garage food.




06 Foreman 500 - 29.5 OG Outlaws, 35%, Warn 2.5k, HL^2", <2.5">, EPI, HMF
95 Fourtrax 300 - 27" Zillas, SS212s , Viper 3k, HL^2"
04 XR80 - Stock
07CRF50 - Stock
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post #8 of 14 Old 07-05-2016, 09:41 AM Thread Starter
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Putting in work......


06 Foreman 500 - 29.5 OG Outlaws, 35%, Warn 2.5k, HL^2", <2.5">, EPI, HMF
95 Fourtrax 300 - 27" Zillas, SS212s , Viper 3k, HL^2"
04 XR80 - Stock
07CRF50 - Stock
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post #9 of 14 Old 10-23-2016, 07:12 PM Thread Starter
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Hit up Test And Tune Friday night. The truck actually towed decently with the lowering kit (trailer properly loaded of course), and the new found power (headers, tune, awd delete) was really noticeable.


06 Foreman 500 - 29.5 OG Outlaws, 35%, Warn 2.5k, HL^2", <2.5">, EPI, HMF
95 Fourtrax 300 - 27" Zillas, SS212s , Viper 3k, HL^2"
04 XR80 - Stock
07CRF50 - Stock
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post #10 of 14 Old 01-11-2017, 09:42 AM Thread Starter
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So I noticed when loaded these djm springs are a little on the soft side. The stockers even with with the auto leveling not working still handled load well. I knew I needed to address this. I inquired about an air spring kit for lowered vehicles and they told me I need to measure. Once I got my measurement I ordered a custom fit kit for the rear coil springs. I figured it would be a good time to retire the probably original 200k mile shocks also.





Here is a pic of the stock shocks with the blown out air bladders plus the compressor that was mouted to the framerail.



Here is the rear end sagging, and the new air spring helper installed.



I routed the lines, T'd them together and ran it to a schrader valve i installed near the hitch. They fill up really quick with the shop compressor, think bycicle tire quick.



Driving/Towing results to come.

06 Foreman 500 - 29.5 OG Outlaws, 35%, Warn 2.5k, HL^2", <2.5">, EPI, HMF
95 Fourtrax 300 - 27" Zillas, SS212s , Viper 3k, HL^2"
04 XR80 - Stock
07CRF50 - Stock
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post #11 of 14 Old 01-11-2017, 09:45 AM
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looks cool!

I've got mine up for sale. Going back to a truck. I miss having a truck.


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post #12 of 14 Old 03-02-2017, 09:09 AM Thread Starter
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So I decided I wanted a little more performance, and towing prowess. I ordered some blue box Motive 4.30 gears, part number GM10-430 and a Ratech rebuild kit. I also ordered a Ratech solid pinion spacer. I decided a new cover would be nice also.



Motive gears and cover.



Opened it up and found an open differential. I wasn't too thrilled about this, I figured it had the g80 locking diff. Only thing I can figure is because it was full time awd they skipped the locking diff.



Found a buddy who had a g80 sitting in his garage across town. So I drove over and got it. Here I was passing The Strand Theatre, it is an old and decorative building. Apparently I was missing the concert.



Here's the g80 and the stock diff:



Basically there are two bearing sizes for these diffs. The problem is its not just the diffs that are different its the actual housing that's machined bigger. So the deal is you have a small bearing that mates with some diffs and housings, and a larger bearing that mates with other diffs and housings. You dont know what you have until you measure it. The s10 the g80 came out of has the small bearing, and my housing is machined for the larger bearing, and they dont make a bearing that will make it work. So, back to open diff I go. I set the gears up for those interested at 10 pinion preload with no seal, 20 with seal, and 30 with carrier and backlash was about 5/6. I used a 40 shim under the pinion bearing and the pattern was perfectly centered and egg shaped, no hard lines. I was very happy with how these gears went together. I did have to bend the stock panhard bar just a tad to clear the cover.



Driving impressions: light throttle acceleration is very easy, motor never works hard, the converter tightened up its manners and feels really close to stock at light throttle. Hwy cruise it accelerates easily without unlocking the converter. And the little bit Ive rolled into the throttle the rpms climb really quick. Cruise rpm is about 2500 @ 80, and climbs up pretty quick from there if you increase speed. The truck is on 31 inch tires.

06 Foreman 500 - 29.5 OG Outlaws, 35%, Warn 2.5k, HL^2", <2.5">, EPI, HMF
95 Fourtrax 300 - 27" Zillas, SS212s , Viper 3k, HL^2"
04 XR80 - Stock
07CRF50 - Stock
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post #13 of 14 Old 04-03-2017, 08:53 AM Thread Starter
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Finally got to tow with the new bags and gears, much much better. It controlled the trailer well and accelerated with ease. Only got two passes for the night....



I noticed over some swooping type bumps that the front had a little less control then I liked. The good news is I have had new parts on the shelf waiting for a while. I figured, well, time to wipe the dust off them and get them installed.



Part numbers for upper balljoints, lower balljoints, outer tie rods, and shocks.



Right now Im lowered on the stock keys, and they are basically at the lowest setting. The height is ok but I hate that there is no more adjustment, I wouldnt have minded another 1/2 lower. So I bought these 2" drop spindles a while back. The idea is to install them, then be able to raise the keys back up so I have some room to fine tune.



Going for an alignment soon. At 200k miles the balljoints/tie rods were original and surprisingly had no slack in them. The shocks were still functioning within reason also. The reason for replacement is the boot recently deteriorated and started throwing grease inside the wheel. I did notice the swaybar end links had slack in them so I will be ordering them soon.
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06 Foreman 500 - 29.5 OG Outlaws, 35%, Warn 2.5k, HL^2", <2.5">, EPI, HMF
95 Fourtrax 300 - 27" Zillas, SS212s , Viper 3k, HL^2"
04 XR80 - Stock
07CRF50 - Stock
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post #14 of 14 Old 04-30-2019, 12:26 AM
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do you know how much the towing capacity of 2004 Yukon XL? can we use it for roadside assistance nyc?
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