Rocket Man's 02 Denali Build Thread AKA "THE BEAST"

[Rocket Man]

Does the plastic just get brittle? Genuine GM?

AC Delco switch. If you’ve ever pulled one off you’d know they’re a *****. Not sure why, the plastic just grabs at the shaft and it’s a real tight fit. I tried wiggling this one on after being sure it was lined up but no matter how I tried it would only go halfway so I tried tapping it on with a hammer and it broke. I’ll try grease next time I guess.

 

[bottomline2000]

AC Delco switch. If you’ve ever pulled one off you’d know they’re a *****. Not sure why, the plastic just grabs at the shaft and it’s a real tight fit. I tried wiggling this one on after being sure it was lined up but no matter how I tried it would only go halfway so I tried tapping it on with a hammer and it broke. I’ll try grease next time I guess.

That's funny because I couldn't unplug mine lol. It slid of off fine. I just left it and plugged it up to the new trans. At least it won't disconnect.

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[Rocket Man]

That's funny because I couldn't unplug mine lol. It slid of off fine. I just left it and plugged it up to the new trans. At least it won't disconnect.

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Yeah that’s the other thing with them. The factory puts some kind of glue inside the connector that makes it a ***** to pull apart. I had to replace the switch another time when my front driveshaft came loose after breaking a u-joint and destroyed it. I don’t remember what method I used to unplug it. So now that I remember that time, this will be my third replacement switch.

 

[bottomline2000]

Not to completely derail this build thread but I found a NVG149 transfer case adapter for the 4l80 ..I had no idea the part cost almost$500.can u say markup?!.would this be the only missing link for the Denali 80e AWD swap?

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[Rocket Man]

Not to completely derail this build thread but I found a NVG149 transfer case adapter for the 4l80 ..I had no idea the part cost almost$500.can u say markup?!.would this be the only missing link for the Denali 80e AWD swap?

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Yep that’s it. I’m not ready to make that swap, probably won’t anytime soon. But yeah, I knew the guy that machines them wants that much. Ridiculous.

 

[Rocket Man]

Its happening. As you can see from the flex plate pics, there’s no way to get spacers in unless you glue them in beforehand like I did. I can barely get a ratchet on, and only 1 click at a time with a 1/2” drive torque wrench. I’m resting up before I manhandle the transfer case into position. Then all I have left is the starter, drive lines, exhaust, plugs and fluids.

 

[randeez]

Not to completely derail this build thread but I found a NVG149 transfer case adapter for the 4l80 ..I had no idea the part cost almost$500.can u say markup?!.would this be the only missing link for the Denali 80e AWD swap?

Sent from my SM-G975U using Tapatalk

i seem to remember the price of these slowly going up over the past 5 years since he's been machining them, started out at like $350 iirc.
unfortunately he's the only game in town for it, so he can charge whatever he wants lol. the other "option" is to build an 80e with the 60e output shaft, which isnt much better than just building a 60e.
I have been following only because i am interested in the older AWD case, with the viscous coupling, should be a good improvement over the 'open" style BW i have now. pretty sure that input shaft will also work with the 6l80 I have now.

 

[Doubeleive]

maybe put a socket over that neutral switch and tap it on that way?, they are flimsy crap metal and plastic

 

[Rocket Man]

maybe put a socket over that neutral switch and tap it on that way?, they are flimsy crap metal and plastic

I got it on by tapping with some flat stock right around the shaft. Once it got past the outer edge it slid right on.

 

[Rocket Man]

I decided to quit for the day after about 8 hours straight. The transfer case kicked my ass. I put it on my stomach and pushed it up until I could tuck the tail over the rear frame crossmember and then realized the engine/ trans was hanging too low so the angle wouldn’t let me slide it on the tail shaft. I was able to reach the trans jack with one hand while I held the front of the tc with the other, roll it under, and jacked it until it ran out of lift, a few inches short. Dammit! I balanced it best I could, climbed out and grabbed a couple 2x’s and was able to get them under the tc and jacked it until I could slide it in place. And then I had to fill it with fluid which was a *****. Should have done that first. Then the starter fought me. Then the header and passenger side plugs were fun. I started on the exhaust but by then I was tired and everything fights me when I’m tired so I decided to finish tomorrow. Just need to finish the exhaust, install drivelines and driver side plugs, fill with trans fluid and take it off the stands. Almost there!