Project 99 Yukon

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My99Yukon

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PROJECT 99 YUKON REHAB

Hey All,

I am new to the group and I am excited to see all of the cool builds and expertise on this forum.

About Me:
I have never wrenched on a vehicle but after a few hairy moments in my old 1999 Yukon with now 186K, it was either time to sell it or rehab it. This seemed like the perfect opportunity to work on an older truck that was depreciated but had value to me. So the project began.

Before:

20160627_131520.jpg

After:
20160909_125022.jpg

20160909_125100.jpg
The journey started because I discovered that the 265/75/16's were too big for the stock wheels. I was loaded up and coming home from a long trip with a lap through the Rockies for a few weeks when i stopped into get a new spare where I had bought my original tires. They would not put a spare tire on old rim so I was either forced to retire back to 245's or get new wheels. That decision was easy. I put some American Outlaw 16x8's on and continued the trip. The Yukon was immediately more friendly to drive, took corners better and I felt like I had a new truck in my hands.

On another trip, under bad weather and heavy braking, the Yukon dove to the right (scared the s*** out of me). At 137K, my original engine block cracked...probably from the dexcool so I replaced the engine. This seems to be a typical outcome for many of these motors. At 178K, and a pretty new motor, I made the decision to start the rehab.

The Rehab:

Weekend One

Rear Output Shaft Seal
Shocks - Rear
Tie Rod, Outer
Tie Rod, Inner
Ball Joint, Lower
Ball Joint, Upper
Shocks - Front
Brake Pads - Rear
Brake Spring Assembly - Rear
Brake Drum Assembly - Rear
Brake Rotors - Front
Brake Pads - Front
Fluid, Flush & Fill
Bump Stop - Front
Bump Stop - Rear
ABS Sensor Cable, Right
Alignment

Weekend Two

Engine Oil & Filter
K&N Filter 2001
Dura Lube HL-44001-12 5.25oz Upper Cylinder Lubricant
Mobil 1 (120766) Extended Performance 5W-30 Motor Oil
WIX Filters - 33481 Fuel (Complete In-Line) Filter,

Coolant Flush & Fill -
Prestone Super Flush/Cleaner 4 times;
Prestone Extended Life 50/50
(Switched Back to nice green Ethylene Glycol because some sleepy tech had turned my radiator fluid into brown sludge when they mixed coolants)
Radiator Cap 15 psi;
ACDelco 131-151 GM Original Equipment Engine Coolant Thermostat

Front Differential Oil D/F
Pennzoil 550042102 Axle 80-W90 (GL-5)

Transmission Fluid & Filter Exchange -
Red Line 30504 D4 Automatic Transmission Fluid
WIX Filters - 58847 Automatic Transmission Filter

Rear Differential Gear Oil - R/R R/R Case, replace seal, clean,
Pennzoil 550042102 Axle 80-W90 (GL-5) Gear Oil

Intake Manifold Cleaning
Scraping and SeaFoam into Throttle Body

Throttle Body Cleaning
CRC BRAKLEEN Chlorine-Free Brake Parts Cleaner - Low VOC

C0ld Air Intake
K&N Performance Cold Air Intake Kit 57-3013-2 with Lifetime Filter

CPU Reprogramming
Hypertech 32500 Max Energy Power Programmer

20160824_173843.jpg


20160824_185624.jpg

Weekend 3

Coolant Pump
AC Delco Professional Water Pump 252-711

Motor Mounts
Energy Suspension; 355-3-1121R

Transmission Mount
Energy Suspension; 355-3-1129R

Headers
Gibson Stainless Steel Ceramic Coated; 462-GP102S-C

Cat Converter
Magnaflow 23453 Direct Fit Catalytic Converter (Non CARB compliant)

Oxygen Sensors
Bosch 15703 Oxygen Sensor-Upstream
Bosch 13474 Oxygen Sensor-Downstream

Cat-Back Exhaust & Muffler
Magnaflow 15701 Stainless Steel Single Cat-Back Exhaust System

B0dy Mounts
Prothane 7-136 Red Body and Cab Mount Bushing Kit - 20 Piece


Weekend 4

EGR Valve
ACDelco 214-1080 GM Original Equipment EGR Valve

Transfer Case Motor
Dorman 600-901 Transfer Case Motor

Backup lights
Nilight 2PCS 6.5" 36w Flood LED

Backup lights Wiring Harness
LED Light Bar Wiring Harness Kit 40 Amp Relay On/off Switch

Key Fob Replacements KeylessOption Keyless Entry Remote Control Car Key Fob Replacement for 16245100-29

Spark Plug Wires
Taylor Cable 74236 Spiro-Pro Red Spark Plug Wire Set

Spark Plugs
NGK (7397-4PK) TR5IX Iridium IX Spark Plug, (Box of 4)

Front Sway Bar Bushings
Prothane 7-1114 Red 1-3/16" Front Sway Bar Bushing Kit

Four Wheel Drive Switch
Dorman 901-130 Four Wheel Drive Switch

Transfer Case Slip Yoke Seak NAPA; 19317
Drive Shaft, Rear, U-Joints, Both NAPA; UJ235
Drive Shaft, Front, U-Joint Regrease
Interior Cabin LED
Spark Plug Wire Harness
Transfer Case Fluid; Flush & Fill AutoTrak II
Exhaust Hangers, Rubber

Weekend 5

Built a sleeping and storage platform (pictures to follow on this and the other mods)

Path Forward:

Torsion Key and Block Lift
Heavy Duty Shocks
285's or 33's or just stick with the 265's but something like the BFG K02's
Rear swing-out for spare and extra range
Front bumpr
Custom Steel Top Rack
Dual Batts
Solar charging system
Redo my sleeping and storage system
Rebuild Transfer Case
Regear (Maybe 4.10 depending on the KO2's I can stuff in there)
HF radio/antenna

The build will be time limited (but mostly cash limited) so I will chip away at the project one step at a time when I can. I look forward to learning, sharing and building out my rig with you all.

- JC

 
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My99Yukon

My99Yukon

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Plastidipped the badges and fading rubber.
20160903_100549.jpg

K&N Intake
20160824_210554.jpg
Gibson Headers With Magnaflow exhaust and 3" tip.

Gibson Headers.jpg

For the mountains... the sleeping and storage platform. This needs some work but it is a starting point. The top shelf extends to just behind the front seat for 75" of platform when the rear seats are folded down.

20160714_182047.jpg
 

Miami-Dade

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Welcome from Miami Beach Jon!! Your 99 Yukon looks awesome!! Nice work..All those weekends working on your Yukon paid off.
 
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My99Yukon

My99Yukon

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Thanks Gary. I am proud of what I have done so far with a bit of youtube learning and no past experience. I have a few mechanical things to fix (ie. pay someone to fix the transfer case. I dont want to tackle that) before I head back to the mountains. A lot of the stuff can wait. Once I fix the 4L issue, it will be back to the capable truck that it has always been. Reliability is my main focus and that is why I chose to rehab the truck. Simple, basic Truck. 5.7L. Not too many computers. not too hard to work on and pretty fun to get to the mountains with.
 
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My99Yukon

My99Yukon

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Energy Suspension and Prothane Upgrades

I am not sure which upgrade is my favorite. The Gibson headers and Magnaflow sound amazing. The K&N CAI is great and I think really adds to the system with the new exhaust. The Hypertech programmer is a huge change for firmer shifting and power. I definitely notice that add-on.

But of all, I think the poly upgrades changed the entire dynamics of the truck.

The motor mounts were shot.

Old motor mount.jpg


New Energy Suspension Motor Mounts with cleaned and painted casings.

New Motor Mount.jpg

Can I tell you what a total PIA that was? Wow!

I think the dealer wanted 700-800 aside and that was ridiculous. So I did the motor mounts, body mounts, transmission mount (all Energy Suspension) and front sway bar bushings (Prothane) and the difference in handling was such a huge improvement. I would always recommend this and except for the motor mounts the job was not that hard.
 

bunchz71

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Looks good. With the bottom plate of the throttle body flapper that black, I would suspect your fuel pressure and spider injectors would need to be replaced. When the fuel regulator goes bad, or the injector lines get brittle and crack, the engine runs rich and probably smokes a little. Its a pretty simple job, but would put you back about $300. It made a huge difference on my 99 Hoe.
 

RED TAHOE LS

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Jon welcome to the forum from Georgia Dawg country. You mentioned you have not wrenched much in the past, you have done one hell of a job on the Yukon, so keep up the good work. Good luck and keep posting future changes.
David g.....:)
 
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My99Yukon

My99Yukon

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Looks good. With the bottom plate of the throttle body flapper that black, I would suspect your fuel pressure and spider injectors would need to be replaced. When the fuel regulator goes bad, or the injector lines get brittle and crack, the engine runs rich and probably smokes a little. Its a pretty simple job, but would put you back about $300. It made a huge difference on my 99 Hoe.

Thanks for the feedback. After the Dexcool killed my block, I replaced the motor with a crate motor about 40k-50k miles ago in December 2010. Would the mechanics have replaced the spider injectors as part of that? That seems like a big job to lift the top of the motor off to replace that part. I will check the fuel regulator in the morning and see if there is any of the cold start issues like long crank but I dont think I remember any of that in the past. perhaps the build up is from before the engine was R/R'd. Your thoughts?
 
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My99Yukon

My99Yukon

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Jon welcome to the forum from Georgia Dawg country. You mentioned you have not wrenched much in the past, you have done one hell of a job on the Yukon, so keep up the good work. Good luck and keep posting future changes.
David g.....:)

Thanks for your support. I have never wrenched before so this is my life experiment to demystify what the mechanics do everyday. My goal was to have a minimum baseline of understanding how this beast works so if I got stuck somewhere, I would have a starting point for troubleshooting and determine if the problem was outside my scope of knowledge. Plus, it is pretty satisfying to fix something on the cheap that might otherwise be an outrageous expense that makes you want to unload the vehicle.

I am finishing some rock sliders, rear bumper and hitchgate. I will get that posted when I am done in the next few days with some pics. My goal for this project was to get some increased departure angle, get the spare tire to a place where I could actually get to it in the event of a problem and carry some spare fuel on the outside of the truck besides on the roof rack. Keep you posted!
 

bunchz71

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Thanks for the feedback. After the Dexcool killed my block, I replaced the motor with a crate motor about 40k-50k miles ago in December 2010. Would the mechanics have replaced the spider injectors as part of that? That seems like a big job to lift the top of the motor off to replace that part. I will check the fuel regulator in the morning and see if there is any of the cold start issues like long crank but I dont think I remember any of that in the past. perhaps the build up is from before the engine was R/R'd. Your thoughts?
If you replaced the motor with a long block (block with heads and no intake, i would suspect they used the same injectors. Check youtube for changing spider injectors. There are several videos that are very helpful.
 

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