strutaeng's 04 2500 4x4 project Suburban

[RAMurphy]

Nice job. Body work was never a talent for me.

 

[Geotrash]

Nice job. Body work was never a talent for me.

Same. This work is inspiring for me because I have an '07 that will need paint in the next few years.

 

[strutaeng]

Same. This work is inspiring for me because I have an '07 that will need paint in the next few years.

I painted the hood on my first car, 99 Chevy Malibu back in college. When I bought it, it was in a collision and they had repainted the hood and it faded within 2 years. I used a generic Porter Cable spray gun and 6 gallon compressor. The results were fair, but had horrendous orange peel. SMH

The good news is that today, there are SO MANY good spray guns out there! It's unbelievable. I did all of this work with that gun from Amazon (Aeropro A610) I linked in there BTW. It used to be only guys actually doing this professionally could afford those expensive sprays guns. But you gotta give credit to the Chinese here for creating clones, LOL. And all of the knowledge on the YT videos is amazing too.

Check this video out:

BTW, I did find the roof rack mounting pads at the junkyard. I painted them and finally reinstalled it yesterday...a little side job I decided to do, is paint these DIY speakers I put together with my son. It has everything you need, just assemble the cabinet and put together the crossovers. Used the same paint as what I used on the roof rack pads (and wiper arms). Actually turned out really nicely. It's the C-note kit from Partsexpress. Fun little project

 

[strutaeng]

I came across these guys that have somehow figured out how to put a locker on the front IFS 9.25" axle. Sounds that it's a mechanical locker that automatically locks when the front driveshaft transmits power to the front. The reviewer says it even works in reverse.

Chevy GMC 9.25 Locking Front Differential | Kodiak Truck

Chevy GMC 9.25 Locking Front Differential for GM 1500HD, 2500HD, 3500HD with 6.6 Duramax Diesel, 6.0l and 8.1l gas engine from Kodiak Truck.

kodiaktruck.com

Kinda interesting actually.

The only other option im aware of is the ARB locker, which is like $1300, although you still need an air compressor or tank.

 

[Bigburb3500]

I came across these guys that have somehow figured out how to put a locker on the front IFS 9.25" axle. Sounds that it's a mechanical locker that automatically locks when the front driveshaft transmits power to the front. The reviewer says it even works in reverse.

Chevy GMC 9.25 Locking Front Differential | Kodiak Truck

Chevy GMC 9.25 Locking Front Differential for GM 1500HD, 2500HD, 3500HD with 6.6 Duramax Diesel, 6.0l and 8.1l gas engine from Kodiak Truck.

kodiaktruck.com

Kinda interesting actually.

The only other option im aware of is the ARB locker, which is like $1300, although you still need an air compressor or tank.

My only concern on this is that it states “once in 4wd the unit locks.” Does this mean you cannot use 4wd or auto4wd when you have bad weather?

 

[strutaeng]

My only concern on this is that it states “once in 4wd the unit locks.” Does this mean you cannot use 4wd or auto4wd when you have bad weather?

I would imagine "locks" means that the mechanical locker engages (both front wheels spin at the same rate) vs open differential.

Not sure how that would work with the AutoTrac NP246? I'm thinking maybe swapping that to a NP261 manual lever transfer case down the road. I believe that's an easy swap. A NP263 (button shift, non-AutoTrac) is another option. Both of those came with the same transmission on the HD trucks I believe, actually I think they are called NP261HD/NP263HD according to their nomenclature. The Internet off-road "experts" on various forums say the NP246 is not very strong, but I really don't know?

 

[Bigburb3500]

I don’t either but my history has been in the Toyota group and many things the “off-roaders” complain about being “not strong” are talking about off-roading where most of the population will and won’t ever take their vehicle lol!
A front locker is just sooo nice for those handful of times that throttling thru an obstacle seems reckless.

 

[strutaeng]

I ordered a new cluster (or remanufactured?) from ISS because mine has a parasitic drain. They were on sale and I got the LED light upgrade and lifetime warranty.

I still have to fix the auxiliary fuel tank sender, which is why it's saying I'm low on gas. I think the little teeth are messed up. I've never had to drop a fuel tank until now...I guess there's always a first time.

 

[strutaeng]

Does anyone know what the color of the headliner is called? I've been kinda holding off this job because IDK what this is called? But I can't imagine this being any different than anything SUV 2 tone out there from this generation, no?

2000 - 2006 Chevrolet Suburban | Headliner Fabric Replacement Kit

3/16" Thick / 60" Wide - Foam Backed Headliner Fabric Roll Length will be cut to fit: Chevrolet Suburban (2000, 2001, 2002, 2003, 2004, 2005, 2006) Please select the applicable color and fabric length options for your vehicle. Selecting to add fabric for the sunroof sha

www.moonautotops.com

My brother suggested I just ordered something that matched the darker gray color like on the pillar interiors...but what is that?

Dang, I hate this mix-matched interior colors on the SUVs...who the hell thought this was a good idea? Lmao

Someone just pick me a color! I can post the RPO code if that helps...

Edit: RPO code is 922

 

[Tonyrodz]

Does it look light gray-ish? If so it's probably light pewter.

 

[strutaeng]

Does it look light gray-ish? If so it's probably light pewter.

Yes, it's a light gray.

I actually ordered the smoke color from that chart so I hope it matches closer the pillar plastics.

 

[Fless]

Does anyone know what the color of the headliner is called? I've been kinda holding off this job because IDK what this is called? But I can't imagine this being any different than anything SUV 2 tone out there from this generation, no?

2000 - 2006 Chevrolet Suburban | Headliner Fabric Replacement Kit

3/16" Thick / 60" Wide - Foam Backed Headliner Fabric Roll Length will be cut to fit: Chevrolet Suburban (2000, 2001, 2002, 2003, 2004, 2005, 2006) Please select the applicable color and fabric length options for your vehicle. Selecting to add fabric for the sunroof sha

www.moonautotops.com

My brother suggested I just ordered something that matched the darker gray color like on the pillar interiors...but what is that?

Dang, I hate this mix-matched interior colors on the SUVs...who the hell thought this was a good idea? Lmao

Someone just pick me a color! I can post the RPO code if that helps...

Edit: RPO code is 922

The link you posted indicates that free samples are available.

 

[strutaeng]

I did order a bunch of color samples and even got an email saying they were delivered, but I didn't get them. USPS is horrible here. I always get the wrong mail and I often wonder if mine goes elsewhere?

Anyways, I received the roll of the headliner yesterday and will check the color tomorrow.

In the meantime, I decided to paint the sail panels. Did my 06 and the 04. I had bought a InoKraft Drizzle D1 and a Neiko minigun, neither of which I had used. I thought this was a perfect job for the minigun, but turned out to be junk. I got drips when I released the trigger. Tried to adjust the fluid control and nothing. When I was cleaning it, the paint was squirting out w/o me pulling the trigger. SMH

So I used the InoKraft and boy was I surprised! Sprays beautifully. No wonder the guys on YT rave about this gun. I'm gonna agree. Highly recommend it.

 

[strutaeng]

Oh, they had stuffed my free samples envelope in the roll of headliner...

Here's what I think was the closest match (?) to my existing headliner, but I ordered the darker color. Second photo shows their number if anyone needs it down the road for their vehicle.

And the sail panels on the 04...

 

[Tonyrodz]

Oh, they had stuffed my free samples envelope in the roll of headliner...

Here's what I think was the closest match (?) to my existing headliner, but I ordered the darker color. Second photo shows their number if anyone needs it down the road for their vehicle.

And the sail panels on the 04...

Looks like you have light pewter, but went with dark pewter. Those pewters.....

 

[Marky Dissod]

…

 

[strutaeng]

Welp, my fuel pump went out. The truck was parked in my backyard and we are moving so the timing was perfect. LOL. I confirmed fuel pressure was zero and relays were working by swapping them.

I ordered both main and auxiliary fuel pump assemblies (recall my rear pump sender I had diagnosed as as bad.) I changed the main fuel pump, but the auxiliary was a BEAR. I removed the spare tire and the crossmember that supports the spare tire, but I couldn't figure out how to disconnect all the hoses to he auxiliary tank...

So I only replaced the main tank pump, and put everything back together. I fired it up and drove it to my brother's house, in the interim...so not sure how to replace that darn Aux. Tank F.P. I checked Charm.li but haven't found the diagrams... TBD, I guess? SMH

 

[Fless]

'04, or '06?

 

[Fless]

Do these help? (for 2004):

Rear tank removal:

Fuel Tank Replacement (Rear Tank) — 2004 Chevrolet Suburban 3/4 Ton 2WD V8-6.0L VIN U Service Manual | Operation CHARM

Detailed repair manual for the 2004 Chevrolet Suburban 3/4 Ton 2WD V8-6.0L VIN U.

charm.li

Fuel Pump and Sender Assembly - Secondary With Dual Tanks — 2004 Chevrolet Suburban 3/4 Ton 2WD V8-6.0L VIN U Service Manual | Operation CHARM

Detailed repair manual for the 2004 Chevrolet Suburban 3/4 Ton 2WD V8-6.0L VIN U.

charm.li

Fuel Sender Assembly Replacement (Rear Tank) — 2004 Chevrolet Suburban 3/4 Ton 2WD V8-6.0L VIN U Service Manual | Operation CHARM

Detailed repair manual for the 2004 Chevrolet Suburban 3/4 Ton 2WD V8-6.0L VIN U.

charm.li

 

[strutaeng]

Do these help? (for 2004):

Rear tank removal:

Fuel Tank Replacement (Rear Tank) — 2004 Chevrolet Suburban 3/4 Ton 2WD V8-6.0L VIN U Service Manual | Operation CHARM

Detailed repair manual for the 2004 Chevrolet Suburban 3/4 Ton 2WD V8-6.0L VIN U.

charm.li

Fuel Pump and Sender Assembly - Secondary With Dual Tanks — 2004 Chevrolet Suburban 3/4 Ton 2WD V8-6.0L VIN U Service Manual | Operation CHARM

Detailed repair manual for the 2004 Chevrolet Suburban 3/4 Ton 2WD V8-6.0L VIN U.

charm.li

Fuel Sender Assembly Replacement (Rear Tank) — 2004 Chevrolet Suburban 3/4 Ton 2WD V8-6.0L VIN U Service Manual | Operation CHARM

Detailed repair manual for the 2004 Chevrolet Suburban 3/4 Ton 2WD V8-6.0L VIN U.

charm.li

Yes! Thank you sir!