2003 Express AWD, tired suspension at 223k, need suggestions

[Unseenthings]

Hi everyone, this will be my first thread since joining this afternoon. I've spent time reading lots of treads here, but don't have a clear idea of which direction I should go.
I have a old express on factory suspension that is getting hard to drive at 223k. It's a 1500 hightop conversion. I've been thinking of dumping it on CL for 2k and seeing if it will go away, but with the recent drop in gas prices I'm thinking of modifying it a bit to sleep in and stop using hotels when I travel for work. I guess I will make my decision based on what I learn in this thread. I came here because I feel you have the most experience in modifying these to handle weight and sway less.
Most of what I've read is about people wanting to lift, I'm not sure I want or need a lift, I have a 2500 4x4 duramax sierra for such things...
However, rarely does replacing stock parts with stock parts make sense. So with it already being a hightop conversion with all the goodies, and a tow package, what would you do?
Does it need new springs at 223k?
Is the 99 suburban spring pack a good choice if I'm keeping stock height?
What shocks to use? Give me the cheap and recommended options. Bilstein shocks for a different model and have them revalved?
Tie rod ends for the front?
Ball joints?
Anything else?
I'm getting a intermittent oil light and needle flux, is it time for oil pump as well? stock or HP?

PS, Thanks for the Truckfridge and ProPex info.

 

[boardrider247]

Nothing wrong with just refreshing the stock suspension.
The suburban spring pack some of us are using is from a 3/4T and is almost 2 1/2" thicker then the stock spring pack. So it wouldn't make much sense to try and use it for a stock height van.
Personally if it were me refreshing that van with the intention of keeping it for some time I would do the following.
-Rear springs and shocks (just good quality replacements nothing fancy)
-Front torsion bars and shocks
-Ball joints
-Tie rods and ends
-Sway bar bushings
-Look at the rack/pinion replace if needed
I would also look at the front CV joints and the Ujoints in the driveshafts

It is a long list but by the time you get over 200k much of that stuff has outlived it's normal lifespan.
And if you decide to sell shoot me a PM. I may need another AWD van:sombrero:

 

[simple]

Is there much rust on the under carriage body and fasteners?

 

[86cj]

I would guess the bumpstops are deteriorated or possibly gone, both front and back rely on them as part of the spring rate and would be noticeable. I have had success getting the new car feel back when changing the front control arm bushings on other GM torsion front suspensions. Of course replacing worn tie rods, ball joints and even wheel bearings will improve road wander and should be first on your list.

A tight front suspension that handles really well is what makes these AWD fullsize vans pleasant to live with. If you don't buy premium suspension parts you will just be chasing your tail, I don't care if they will exchange a bad part for free forever, I have better things to do than tear down the suspension every year and brag about if not costing any money. You can use front replacement Bilsteins for a stock height 99-06 1500 if you don't lift your van, they don't make front shocks for the AWD Van for some reason. I have heard the oil pump can be replaced and give some more life to an old 5.3 they seem to have some real stamina.

Unless you want to lift it don't put the HD 3/4 ton suburban rear springs on it, BTW they are 1 7/8" thicker not 2 1/2" and give a real 3" lift to the back.

 

[Unseenthings]

Thank-you everyone for the suggestions. The van is pretty rusty around the edges.

 

[Unseenthings]

Will suspension kits for 4wd 1500's have everything I need?
Will these Bilsteins work?
BILSTEIN 4600 SERIES FRONT & REAR SHOCK KIT
BILSTEIN FRONT PART #24-065009 / BILSTEIN REAR PART #24-029056

 

[TeleSteve]

Part number 24-065009 will work for the front, but you would need Part Number: 24-024815 for the rear with stock height springs. The rear top mount is different on the vans.

 

[Unseenthings]

How do i determine my sway bar size? I see several sizes listed for bushings.

 

[agelessGIANT]

Looking to do these upgrades in the coming months (my van rolled 200k in Nov) and wanted to start ordering parts..Who are the "premium" vendors of these parts for our vans? Looking for some feedback on parts people have experience with or have installed.

Also to the OP, what did you end up doing with your van's "refresh"? I also have a 2003 AWD.

Thanks in advance!

 

[Unseenthings]

After getting no "must haves" recommended, I ended up ordering everything from Rock Auto. They list parts by economy, oem, and performance. I picked a mix of oem and performance parts. I've had success with Moog in the past, and used them again. As expensive as it all came to, BILSTEIN was too rich for me, so i picked the performance Monroes. Too late I learned that some(mine)conversion vans/hightops do take different shocks than other vans as they are shocks labeled for Recreation Upfitter package(YF7). I guess they are for the added weight. All said I did over 1000 miles on the new stuff over the holidays, and while the ride is much improved, I feel there is still too much body roll, and need to know what to do to stiffen it up.

 

[agelessGIANT]

Thanks for the info and update. My suspension bits are tired as well and need a refresh. Ill post up my results when I get around to this but it will be sooner than later.