04 Tahoe Z71 Project

[LTG515]

Thought I would slap together a little thread for the work I’ve been doing, and will be doing, on my 04 Tahoe Z71. I got it with 142k miles on it as a daily driver and am wanting to turn it into a light off roader.

I don’t have any pictures of it stock when I first got it, but I had to replace the instrument cluster right off the bat.

First step was taking the running boards off for a little more clearance and a cleaner look. I also turned the torsion keys up just a little to come level. Didn’t need any re-indexed keys. I’ll be wanting to put some sliders on in the future.

Next thing I wanted was a new bumper. I didn’t like any of the commercially available options for these Tahoes, so thankfully I’ve got a brother in law who’s a great fabricator. Went for a hybrid style bumper. It’s essentially done, just need to paint it up. I’ll be painting it with raptor bed liner.

Speaking of raptor bed liner, I started to paint my fender flares with it, but I grossly underestimated how much I would go through and I ran out. HA! Spraying this stuff isn’t too bad now that I’ve done it once, but the inaugural spray was pretty stressful! I’ve ordered some more so I can finish the rest of the fender flares and the bumpers, and the next go will be less stressful.

I also did a couple electrical things. Got Apple car play which is super nice, put in a reverse camera, and did a little DRL and headlight replacement/mod.

Some things on the horizon:
I’ve got a suspension refresher coming soon. Ordered Bilstein 5100s all the way around, new bumps, and new coil springs in the back. Those should be here soon and will update. Also hoping to put some 285/70r17 (33s) Grabber ATx’s on once I get some tax return money haha! I’ll also update when that happens as well. I currently rub the rear wheel well liner at full flex (even with 265s) so I’ve read I may need wheel spacers to avoid that if going with a bigger tire. I’ll cross that bridge when I get to it.

This forum has already been super helpful for me with figuring some things out, so I wanted to make this for others to read through if interested and also to continue to get some great advice from you guys!


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[HiHoeSilver]

Welcome, and great start! I'm running the ATX in a 275/70r18 and they have been great.

 

[LTG515]

Welcome, and great start! I'm running the ATX in a 275/70r18 and they have been great.

Oh very nice! I feel 275 is an ideal width, just wish they had a 33 with those dimensions in a 17. I think it’d be like 275/75 17 or something but those aren’t options hah.


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[mijohnst]

Nice job! Thanks for posting pictures of what you've done so far. I look forward to seeing more as you move through it. I recently bought a 2005 Tahoe and I've been going through it and fixing all the issues I bought it with (airbag sensors, replacement of heater core, O2 sensors, breaks, tires, etc) and this forum has been immensely helpful.

I really like what you did with those fender flares and I think I'm going to do the same thing. Did you take them off to spray them or just leave them in place? I'm fixing to take my running boards off too. I'd like to find a good used set for tubular nerf bars as a replacement. I'm on the lookout for those.

 

[LTG515]

Nice job! Thanks for posting pictures of what you've done so far. I look forward to seeing more as you move through it. I recently bought a 2005 Tahoe and I've been going through it and fixing all the issues I bought it with (airbag sensors, replacement of heater core, O2 sensors, breaks, tires, etc) and this forum has been immensely helpful.

I really like what you did with those fender flares and I think I'm going to do the same thing. Did you take them off to spray them or just leave them in place? I've fixing to take my running boards off too. I'd like to find a good used set for tubular nerf bars as a replacement. I'm on the lookout for those.

Hey thanks! I left the fender flares on and just taped carefully because I heard that the double sided tape holding them on is really hard to clean off. I didn’t want to have to take them off, have a hard time cleaning the old tape goo, then use new tape to put them back on. It would make for an easier spray for sure, but just something I decided not to do.


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[mijohnst]

Hey thanks! I left the fender flares on and just taped carefully because I heard that the double sided tape holding them on is really hard to clean off. I didn’t want to have to take them off, have a hard time cleaning the old tape goo, then use new tape to put them back on. It would make for an easier spray for sure, but just something I decided not to do.


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Well, you did an excellent job. I wish also wish I had a brother-in-law that could make cool looking for things like that. My brother-in-law is a dud.

I'll probably pull my fenders off with the stone guard, and bumpers off to spray them. I love that all-black look. Keep posting pictures as you move along!

 

[mijohnst]

Hey thanks! I left the fender flares on and just taped carefully because I heard that the double sided tape holding them on is really hard to clean off. I didn’t want to have to take them off, have a hard time cleaning the old tape goo, then use new tape to put them back on. It would make for an easier spray for sure, but just something I decided not to do.


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Quick question for you... You said you didn't buy enough of the Raptor spray. How much would you say you'd need for just the 4 fender flares?

 

[LTG515]

Quick question for you... You said you didn't buy enough of the Raptor spray. How much would you say you'd need for just the 4 fender flares?

I initially bought this:


Custom Coat Black 0.875 Gallon Urethane Spray-On Truck Bed Liner Kit with Spray Gun with Regulator https://www.amazon.com/dp/B00FFIIHHU/ref=cm_sw_r_cp_api_i_S-kmEbMMV8B23

4 bottles of black, one bottle of hardened, and one gun. Custom coat is the same as raptor. Under the same overarching company. This gave me enough to do my front 2 fender flares and my rear bumper plastic trim pieces. I ordered another set of this which I’m sure I’ll be able to finish everything in. I think what makes you go through a lot is that it’s recommended to stand pretty far back because of the high pressure, so it causes a lot of wasted over spray. If you’re taking your flares off, that might help you conserve some paint by having the overspray land on the other flares haha.


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[mijohnst]

Thanks for the feedback! Very helpful! I'm thinking now of just taking them off and running them by a place that does this already. I'm good at mechanical stuff...not so much painting. lol

 

[LTG515]

Thanks for the feedback! Very helpful! I'm thinking now of just taking them off and running them by a place that does this already. I'm good at mechanical stuff...not so much painting. lol

For sure! Yea it’s a little stressful not gonna lie haha but it’s doable. Post about how it comes out.


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[LTG515]

Suspension came in today! Here’s what I ended up going with. Pretty common in here but figure I’ll list it clearly.

Bilstein 5100 front - 24-186643
Bilstein 5100 rear - 24-187237
Moog coils (apparently Z71 spring) - 81069
AC Delco front bump stops - 15153959

Interesting note about the bump stops. From most of my research, I found that the only front bumps available were the 15153958 ones. They’re the ones that look like a dog chew toy. However, I have a Z71 and looked at my current bumps and they don’t look like that. I looked all through rock auto, Amazon, and other sites and could only find the chew toy ones. I ended up finding the 15153959 part number on this forum and looked those up. GMPartsGiant has them listed as fitting the Z71 Tahoe but the item is discontinued (https://www.gmpartsgiant.com/parts/gm-bumper-15153959.html). I then typed that part number directly into rock auto and sure enough it pops up, but not as being apart of any model of Tahoe.

SO, to save yourself a headache, 15153959 is the OEM Z71 front bump and is listed on rock auto if you type it in, otherwise it will not show up.

Hopefully I’ll get around to installing this setup soon!

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[LTG515]

UPDATE!

Bedliner paint job is done. I had enough bottles (5) to finish the rear fender flares, rear lower quarter panel, stock bumper trim, and my new metal bumper. Of course being a DIY spray job there are some flaws, but overall I’m super happy with how it came out! I also have a rattle can of rust oleum bed liner for little touch up areas.

Also, I got my Bilstein 5100s installed with new coils in the rear and new bumps in the front. Because of the springs being new in the rear, I gained a little height, so I also turned my torsion keys almost all the way up. I’m going to let the springs break in before I adjust the keys again, but I’ll likely be turning then down a half turn or so. Otherwise, the install was easy and the ride is much smoother so far!

Only thing left on my list are some new tires. Those will be on soon I hope!


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[HiHoeSilver]

UPDATE!

Bedliner paint job is done. I had enough bottles (5) to finish the rear fender flares, rear lower quarter panel, stock bumper trim, and my new metal bumper. Of course being a DIY spray job there are some flaws, but overall I’m super happy with how it came out! I also have a rattle can of rust oleum bed liner for little touch up areas.

Also, I got my Bilstein 5100s installed with new coils in the rear and new bumps in the front. Because of the springs being new in the rear, I gained a little height, so I also turned my torsion keys almost all the way up. I’m going to let the springs break in before I adjust the keys again, but I’ll likely be turning then down a half turn or so. Otherwise, the install was easy and the ride is much smoother so far!

Only thing left on my list are some new tires. Those will be on soon I hope!


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Looks awesome. Like a border patrol unit. What kind of liner did you use?

 

[Dantheman1540]

I like this a lot!

Since I got my 2wd Tahoe I've dreamed of 4x4 converting it with a nice mid travel kit in the front and stuff some 35s in with minor trimming. I can't believe these trucks aren't more popular in the overlanding crowd. Room for up to 7 people a V8 and cheap as heck. Seems much better than a jeep to me.

 

[LTG515]

Looks awesome. Like a border patrol unit. What kind of liner did you use?

Haha yea kinda like a border patrol unit! I used Custom Coat bedliner which was (maybe still is) a partner product to Raptor bedliner.


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[LTG515]

I like this a lot!

Since I got my 2wd Tahoe I've dreamed of 4x4 converting it with a nice mid travel kit in the front and stuff some 35s in with minor trimming. I can't believe these trucks aren't more popular in the overlanding crowd. Room for up to 7 people a V8 and cheap as heck. Seems much better than a jeep to me.

Thanks a bunch! And yea I agree, I’m surprised they’re not more popular either. The older full sized SUVs like this are roughly similar in dimensions to midsized trucks these days so they’re still practical on a trail. I don’t wheel very hard but I did want to build this up slightly. A mid travel kit would be so cool but don’t think putting that kind of money into this car is worth it for me hah!


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[Dantheman1540]

As you have it now it should be pretty darn capable. I agree about them being considered small now. The new 4 door Tacomas are longer than a NBS Tahoe by at least a foot or 2. Plus the Tahoe 5 link rear setup is actually pretty trick. It has a good amount of travel and really keeps that 10bolt from tweaking one way or another and destroying itself.

 

[LTG515]

As you have it now it should be pretty darn capable. I agree about them being considered small now. The new 4 door Tacomas are longer than a NBS Tahoe by at least a foot or 2. Plus the Tahoe 5 link rear setup is actually pretty trick. It has a good amount of travel and really keeps that 10bolt from tweaking one way or another and destroying itself.

Yea I took it out when I first bought it used and was pleasantly surprised! They really are a sleeper SUV when it comes to off road. Once I get my 33s I’ll be set!


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[LTG515]

TIRES

Alright, tires are on! 285/70r17 E load General Grabber ATx. I think they fit the truck really nice and fill up the wheel well perfectly. No rubbing anywhere during daily driving or full lock. I’m pretty certain the rear tires will rub when articulating since my 265s did also, but I’ll see how bad it is and maybe consider spacers. The tire shop set them at 40 psi, which may be a little stiff for me. I might air down a little lower like 35 or so, but if you guys have suggestions on E load tire pressure let me know. Otherwise I’m super happy with how they look and feel, and can’t wait to test them off road!

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[Dantheman1540]

They look great! I've always been a fan of the grabber ATs. I run my KO2s same size and load E at about 32psi all the time. They feel much smoother and they have worn great with occasional rotations. I have close to 40k on them and they have about 30% tread left. Would have more but they have seen lots of burnouts. If I tow I bump it up to 40psi.