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PostPosted: Sun Apr 05, 2015 11:06 pm 
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Joined: Thu May 22, 2008 11:38 pm
Posts: 1935
Location: Lincoln Park, Mi
Year and Trim: 2004 GTO
How did ya end up getting the old studs out?

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-Ryan
2004 GTO....LS1, LSA supercharged 525whp, 6MT
96 SSEi...September 2010 COTM........GONE
04 GTP comp G.... December 2015 COTM........GONE
2013 Audi Allroad Quattro

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PostPosted: Sun Apr 05, 2015 11:29 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
I had to resort to the BFH.

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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PostPosted: Mon Apr 06, 2015 12:28 am 
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Joined: Thu Sep 11, 2014 8:28 pm
Posts: 376
Location: Boonville, Missouri
Year and Trim: 2002 Galaxy Silver SSEi
This is looking great so far, I will be following this thread.

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2002 Galaxy Silver SSEi "Silver Shadow" 181, xxx miles- DD, tinted taillights, 10000k HID low beams, GXP strut brace, carbon fiber overlays, GXP door bezels and vents and Aeroforce Interceptor Gauge, cleared corners, drilled and slotted rotors, painted calipers, Intense Stage 1 Performance package, smoked door reflectors.
2001 Galaxy Silver SE 119, xxx miles- RIP
2007 White G6 Economy 96, xxx miles- Wife's car, carbon fiber inserts, tinted windows.


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PostPosted: Mon Apr 06, 2015 2:20 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
Found the factory wiring schematics for the dual fuel tanks with dual fuel pumps, and compared to mine. The switch on the dash has two wires that run to the selector valve. One is +12v and the other ground, when you flip the switch it reverses the polarity of the wires so that the one that was originally +12v becomes the ground. For the dual fuel pump setup GM just spliced those wires so that one goes to one fuel pump and the other goes to the other fuel pump. So whichever side is hot has power to the fuel pump on that line. Now all I have to do is make sure I get the left pump on the correct wire so that it turns on when the switch is in the left position.

Now I just need refills for my weatherpack connector kit.

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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PostPosted: Tue Apr 07, 2015 10:05 am 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
So I'm now two steps back on the fuel tank valve. My switch is a momentary switch and the valve is motor driven. So those wires are not hot at all times, and can't just tap into that with the fuel pumps. But it looks like that changed in '88 if the wire schematics I found are correct. All the auto parts chains list the same generic valve across all the variations, but the AC Delco OE part is different with no mention anywhere on what the difference is other than to note that one of the aftermarket parts is a universal valve that requires a new/different switch. So I'm not sure what the difference is between the valves, if any, because of course there is much conflicting/incomplete information online.

It sounds like I need to find the valve and switch off a '88+ truck. I think that means a junkyard trip is in order.

Edit: So based on further research, looks like the original tank switch valve for the non-EFI trucks is a simple motor driven valve. When they changed to EFI the valve was updated to include circuitry that only powers the motor during switching, so the 'momentary' power needed is handled in the valve and the switch supplies constant power which is required by the fuel pump. As far as I can tell, all aftermarket valves now have that feature and are backwards compatible in addition to being rated for much higher fuel pressures. Of course, some of that is speculation, I don't have a factory original motor driven valve to verify. At some point in the past, the selector valve was replaced on this truck.

So all I need is a ammeter to test if the valve I already have has the automatic motor shutoff, if it doesn't then I need one that does, as well as the switch from the '87 that is not a momentary switch.

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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PostPosted: Tue Apr 07, 2015 11:03 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
Managed to get brackets mounted for the rear brake hoses.
Image

Yep, that's an H-body bracket!
Image

Somehow I ended up with the wrong rear axle cover gasket, odd that the FF axle would have a different gasket than the SF.

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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PostPosted: Wed Apr 08, 2015 2:05 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
I'm in the process of trying to rebuild the load sensing proportioning valve. Replacements were discontinued years ago. I've manage to de-rustify the housing and take apart the valve side, but the adjuster side is stuck on due to rust. The snap ring came off in 2 pieces, and it's on day 3 of it's soak in evaporust. I've found one seal that's leaking so far, but need to get the adjuster side off to be able to change it. And if you believe the internet, I am the first person to try to do this, so I'll be pioneering replacement parts (snap rings, seals, and anything else that's broken).

Also I think I found a set of GMC aluminum wheels for this.

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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PostPosted: Wed Apr 08, 2015 10:03 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
I didn't get anything done today, because I found these:
Image

From a '07 2500 HD Sierra. Came with center caps, two good Michelin 265-70R17 LT tires, absolutely no curb rash, no oxidation. Brought one of the front hubs with to check the fitment before I got them. Price was too good to pass up.

Also managed to fit all 4 in the SE, with room to spare.

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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PostPosted: Thu Apr 09, 2015 11:49 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
I've managed to get the rear brake lines in up to the proportioning valve location, and the axle is back together and the rear end back on the ground.

Image

Image

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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PostPosted: Mon Apr 13, 2015 3:34 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
Both tanks are plumbed in, need to get refills for my metri-pack kit to change the connectors on the sending units, and finish making the wire harness. I'll be running duel fuel filters, they are temporarily clamped to the frame until I can find a better/real clamp. I ran out of 5/16" line though, so the last run from the tank valve to the engine bay is not done. Also need to get more quick connect fittings from a junkyard to finish the fuel filter connections. Planning to return to the local U-pull today for the clamps/fittings if I can find them.

I ended up getting a new universal tank valve that uses the steady-on switch, rated for 65PSI. All that need to be done is to change the momentary switch in the cab out with the '87 steady on switch.

Image

Image

Image

Image

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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PostPosted: Mon Apr 13, 2015 10:06 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
While I'm waiting for my metri-pack kit refill to get here so I can finish the tanks, I moved on to the front axle shafts. It only took 3 hours of hitting them with a sledge hammer but I finally got both of them apart. I may end up having to replace one of the outer shafts, the yoke on it looked a little thin.

Almost forgot to add, the axle universal joints were in really bad shape. Only one cap was still sealed against the elements, the rest of them were rolling around in rust, and then there's the joint that already blew the roller bearings out. I'm looking into adding some zerk fittings to the new Spicer joints.

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


Last edited by MattStrike on Tue Apr 14, 2015 12:14 pm, edited 1 time in total.

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PostPosted: Tue Apr 14, 2015 10:41 am 
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Joined: Thu Sep 11, 2014 8:28 pm
Posts: 376
Location: Boonville, Missouri
Year and Trim: 2002 Galaxy Silver SSEi
You are making this build in record time

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2002 Galaxy Silver SSEi "Silver Shadow" 181, xxx miles- DD, tinted taillights, 10000k HID low beams, GXP strut brace, carbon fiber overlays, GXP door bezels and vents and Aeroforce Interceptor Gauge, cleared corners, drilled and slotted rotors, painted calipers, Intense Stage 1 Performance package, smoked door reflectors.
2001 Galaxy Silver SE 119, xxx miles- RIP
2007 White G6 Economy 96, xxx miles- Wife's car, carbon fiber inserts, tinted windows.


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PostPosted: Wed Apr 15, 2015 10:16 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
Here are the details on the load sensing proportioning valve rebuild.

This is after disassembly, the rotor pulls off by pulling out the brass center after the snap ring is off. There is a very small oring still inside that seals the red plunger from the rotor section that I didn't have out yet:
Image

And here are the seals. I did not have to replace the plunger seal. The O-rings are HNBR. McMaster-Carr 9403k55 for the rotor seal.
Image

And this is why it was leaking, there was a gash where it's supposed to seal off to the lower O-ring:
Image

Used JB Weld to repair it; picture taken before sanding it flush.
Image

The rotor and housing with the new seal.
Image

The lower O-ring in the valve side:
Image

RTV to seal the rotor from the elements. I coated the whole rotor with a light oil.
Image

Rotor reinstalled with a new stainless steel snap ring:
Image

And back on the truck, with the adjustable stainless linkage to replace the rusted out worn out piece.
Image

This is what the front axle universal joints looked like:
Image

And for some reason the one outer shaft was horribly pitted with rust. So I'll be replacing it as it is getting thin in the yoke area:
Image

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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PostPosted: Wed Apr 15, 2015 10:31 pm 
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Joined: Fri May 23, 2008 12:56 pm
Posts: 4277
Year and Trim: 2005 Saab 9-3 Arc
I am going to have to ask, why not just replace the truck with a better shape one?

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PostPosted: Wed Apr 15, 2015 11:37 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
Because I can fix this one. You are coming to the MI meet to see it, right?

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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PostPosted: Thu Apr 16, 2015 10:02 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
So I had been on the fence about replacing the motor mounts, but when I split them open today they came out of the shells in about 12 pieces. So I'm glad I decided to bite the bullet and get new Energy Suspension poly mounts. The shells are soaking in Evaporust now, should be able to put the back together tomorrow. Really hoping everything works out that I can get the truck back down on all 4 wheels this weekend and have the first test fit of the motor.

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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PostPosted: Thu Apr 16, 2015 10:19 pm 
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Joined: Sat Jan 17, 2015 1:16 pm
Posts: 304
Location: Jackson, MI
Year and Trim: 2004 GXP
I can't wait to see the finished product!! How close do you think it will be to rolling by the time the MI meet happens??

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2004 Bonneville GXP Crimson Tintcoat- Casual fuel gauge | Brake Performance drilled/slotted rotors front and rear| Retrofit Morimoto mini H1 | clear corners | disabled DRL | 3000K HID fogs | 5% tint | K&N | Yakima rack with fairing, bike rails and kayak rack | Intermittent radio display
1995 Bonneville SSE Deep Amethyst Pearl- SSEI tails | 5% tint | 3 12jlw3v2 in custom enclosure -Gone
1991 Bonneville LE Blue- Alloy spokes -Deceased(deer)


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PostPosted: Thu Apr 16, 2015 11:06 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
I should be able to have this done before the end of the month.

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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PostPosted: Sun Apr 19, 2015 9:10 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
Tank wiring is done, remaining lines and fuel filter mounts are coming Monday, the passenger side tank is mounted, ready to mount the other tank, transfer case is ready to go back in, and the new Spicer axle shaft and universal joints are ready for re-assembly.

I got sidetracked with a welding project, so didn't get as much done as I anticipated this weekend.

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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PostPosted: Wed Apr 22, 2015 10:08 pm 
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4759
Location: SE Michigan
Year and Trim: '99 Montana
'04 Dirtymax
'97 Camaro
'92 Trofeo
Both tanks are in now, just need some quick disconnects and mount the filters.

Spicer joints re-assembled:
Image

And I've got the trans valve body out to try and find out why it wouldn't upshift when cold for the first time. Had to put it in neutral then back in gear to get it to upshift and after that is was always fine. Still not finding any glaring issues, some wear on the TCC valve train but that's it. Governor was fine, no stripped teeth on the gear and the roll pin joint was in good shape, and no missing/stuck check balls.
Image

Transfer case all cleaned up and going back in:
Image

Still working out the adapter plate, the one I got is a little thin and the instructions call for a lot of unneccessary block and trans case mods. If the plate were just a little thicker I could use flat head socket cap screws to flush mount them in the adapter plate and bypass all of that sillyness. So I'm going to try to see if I can find a waterjet or something locally (again) that can make one for me at the thickness I want. Should be easy to create my own cad using this one as a template.

And yes, I realize I could just use the trans currently bolted to the 3800, but it needs to be stripped back down again as it lost 4th gear or something. I know the one I had worked other than that one issue.

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The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67


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