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

[Rocket Man]

Also, I got my QA1 panhard bar yesterday. Hopefully it will clear my TA differential girdle but I'm not in hurry to find out. Maybe tomorrow?

 

[Tonyrodz]

I decided, after doing a lot of research, that the gap between the flexplate and converter is OK. It's about .02" over the .187" that FTI spec's (It's .207"). I read in several places that anything under 1/4" (.250") is acceptable and in fact Performabuilt's instructions call for 1/4". So, with that settled, I finished up everything this morning. The hardest part was probably the transfer case, both getting it in place as well as tightening the bolts. I followed the start-up instructions which call for starting it with the wheels off the ground and going through all the gears although I did so very briefly since my transfer case isn't supposed to be operated that way. At first the wheels didn't move and I was a bit worried but after a few seconds they started going. I just ran it through the gears once and then let it down. After adding a bit more fluid, I drove about a mile like instructed and came home and re-checked everything. No leaks. No issues. I took the trans jack back which was a few miles and traffic was horrible but I did hammer it once and it definitely accelerates better with the stall. And it does a full converter lockup at 40 MPH or so which is kind of cool and might help gas mileage when I don't hammer the throttle. I'm gonna take it out again in awhile after a bit of unwinding. The Beast is back!

View attachment 181876 View attachment 181877 View attachment 181878 View attachment 181879 View attachment 181880

Well it's about time! Good for you Red.

 

[bottomline2000]

I decided, after doing a lot of research, that the gap between the flexplate and converter is OK. It's about .02" over the .187" that FTI spec's (It's .207"). I read in several places that anything under 1/4" (.250") is acceptable and in fact Performabuilt's instructions call for 1/4". So, with that settled, I finished up everything this morning. The hardest part was probably the transfer case, both getting it in place as well as tightening the bolts. I followed the start-up instructions which call for starting it with the wheels off the ground and going through all the gears although I did so very briefly since my transfer case isn't supposed to be operated that way. At first the wheels didn't move and I was a bit worried but after a few seconds they started going. I just ran it through the gears once and then let it down. After adding a bit more fluid, I drove about a mile like instructed and came home and re-checked everything. No leaks. No issues. I took the trans jack back which was a few miles and traffic was horrible but I did hammer it once and it definitely accelerates better with the stall. And it does a full converter lockup at 40 MPH or so which is kind of cool and might help gas mileage when I don't hammer the throttle. I'm gonna take it out again in awhile after a bit of unwinding. The Beast is back!

View attachment 181876 View attachment 181877 View attachment 181878 View attachment 181879 View attachment 181880

Congrats on getting running. Got to be a good feeling lol. How big is the stall?

Sent from my SAMSUNG-SM-T377A using Tapatalk

 

[Rocket Man]

Well shit. I just went out to do a few launches with the new trans to see how it did and about 6 blocks from my house, first huge launch, I hear and feel something big break. I heard bad things happening under there and went oh shit. There's fluid of some kind in a huge streak behind and under the truck. Weird, it looks like oil and the front driveline is hanging down. At first I thought it's the front diff is broken open but as far as I can see it's the clamps that hold the u-joint in that broke and the spinning driveline mangled the oil filter and its engine oil all over the road. I'm hoping it's minor but won't know until tomorrow when I can look see. Might just be the u-joints and oil filter. And something with the shift linkage is bent because it would barely go into park. I'm kind of relieved it wasn't the tranny and it looks like it didn't get damaged.

 

[Rocket Man]

But on a better note, before I left home I installed the QA1 panhard bar and the TA Performance rear diff girdle will clear. Yay.

 

[bottomline2000]

Well shit. I just went out to do a few launches with the new trans to see how it did and about 6 blocks from my house, first huge launch, I hear and feel something big break. I heard bad things happening under there and went oh shit. There's fluid of some kind in a huge streak behind and under the truck. Weird, it looks like oil and the front driveline is hanging down. At first I thought it's the front diff is broken open but as far as I can see it's the clamps that hold the u-joint in that broke and the spinning driveline mangled the oil filter and its engine oil all over the road. I'm hoping it's minor but won't know until tomorrow when I can look see. Might just be the u-joints and oil filter. And something with the shift linkage is bent because it would barely go into park. I'm kind of relieved it wasn't the tranny and it looks like it didn't get damaged.

View attachment 181918 View attachment 181919

Woah..Looks like a u joint strap broke. Hopefully the oil filter took the brunt of the damage.

Sent from my SAMSUNG-SM-T377A using Tapatalk

 

[Rocket Man]

Woah..Looks like a u joint strap broke. Hopefully the oil filter took the brunt of the damage.

Sent from my SAMSUNG-SM-T377A using Tapatalk

Yes and no. The oil pan suffered a bit too but from what I can see it was just a fin on the casting that broke off and I don't see any cracks and it doesn't look like it's leaking. I think I got off lucky. Fingers crossed!

 

[bottomline2000]

Yes and no. The oil pan suffered a bit too but from what I can see it was just a fin on the casting that broke off and I don't see any cracks and it doesn't look like it's leaking. I think I got off lucky. Fingers crossed! View attachment 181920 View attachment 181921 View attachment 181922 View attachment 181923

The u joint straps don't look new and how tight were they? It doesn't take much to hold them in place like 9-12 ft lbs..too tight and they break. Cheap insurance to replace them since they form to the u joint and cost $5.

Ill be the first to say glad u ok. Dropping the front driveshaft like that is serious business.


Sent from my SAMSUNG-SM-T377A using Tapatalk

 

[Rocket Man]

The u joint straps don't look new and how tight were they? It doesn't take much to hold them in place like 9-12 ft lbs..too tight and they break. Cheap insurance to replace them since the form to the u joint..

Sent from my SAMSUNG-SM-T377A using Tapatalk

I over tightened them I think. I'm buying all new ones tomorrow, hopefully heavier duty. If they don't have good ones at O'Reilly's I'll get some good ones online. I think I'll get heavier duty U joints too but don't know what's good- Dana? There's some ridiculously priced ones out there.

 

[Tonyrodz]

Wow! You took that calmly. I'm so glad it wasn't anything too serious. Adding tons of power breaks the weaker parts. I hope nothing else breaks like that.

 

[cmc76]

I'm sure there is cheaper out there.
But years ago I bought yokes, straps and driveshaft from dennys driveshaft.
Took everything I threw at it. Never a driveline break after.

 

[bottomline2000]

I over tightened them I think. I'm buying all new ones tomorrow, hopefully heavier duty. If they don't have good ones at O'Reilly's I'll get some good ones online. I think I'll get heavier duty U joints too but don't know what's good- Dana? There's some ridiculously priced ones out there.

I don't think the strength of the u joint was an issue as much as the install. Proper torque spec and u should be fine. I have Moog u joints but had to buy the straps at O'Reillys. For some reason I thought your AWD setup was different and didn't think to mention the straps. I have a 1350 hybrid joint setup but plan to go full 1350 with a Dennys shaft. Dennys uses dana/Spicer u joints so I would think they are stronger. You can see the size difference in the stock vs 1350 size. It may not be necessay with your AWD setup.

Also, you are going to need a blowtorch to get the u joints out if they have never been replaced. They have impregnated plastic holding the joints in from factory and it has to be melted out. If u have clips in the joint u can pull the clips and press the joint out.

Sent from my SAMSUNG-SM-T377A using Tapatalk

 

[Rocket Man]

I was able to replace the one u-joint with a Spicer Life by using a blowtorch. O'reilly's only had one so I'll have to get the other 3 elsewhere. Also swapped oil filters and filled with oil. No leaks. Bent the shifter linkage and it still is a bit stiff but manageable for now. I was working on the final repair, new straps, but O'reilley's gave me the wrong ones twice even though the second time I brought the old one in. So I took an old one to Autozone and they had the right ones, way stronger than the originals, but I had to go to 2 stores to get 4 straps. I wasn't going to leave the original back ones on. But on my last trip, about a mile from home, right in front of the O'reilly's I always shop at, some ******* idiot pulled right in front of me on my bagger and I had about 2 seconds until impact. I hit him at about 35 mph. Dude didn't even see me. I won't go into any details because I don't want to bum you guys out. But it's bad. I'm broken up, my bagger is RIP. But I'm alive.

 

[Fosscore]

Oh man.... Hope it isn't too bad. Sorry about the bike, but better you are intact. Take it easy pal. Your health is all that matters at the end of the day.

 

[PG01]

Jeesussssss Red..... glad youre alive and kicking, sorry about the bike man.....

 

[gat0r]

man, that sucks

prayers out for speedy recovery


its ridiculous that peeps still fail to see motorcycles.

 

[HiHoeSilver]

Holy cow, red! When does it end? Glad you're alright.

 

[93blkongreenpro]

Oh my dam. Get well and take a drink.

Sent from my SM-G955U using Tapatalk

 

[Tonyrodz]

I'm sorry to hear that Red! I'm really glad you're OK. Fukn a$#holes!!

 

[cmc76]

Glad you lived to tell. Give yourself a few days