Astro AWD "Stroverlander"

[Stroverlander]

Once I got rolling on finishing the repairs, I didn't stop to take many photos...

One of the other leaks was minor weeping from the crimp fittings on the transmission cooler lines rather than replace, I picked up some Gates rubber transmission oil cooler hose, fuel injection hose clamps and a loaner line flaring tool. My plan was to cut off the crimp fittings, remove the old rubber hose, flare the ends and reinstall. I did most of that, basically. Because the loaner flaring tool wasn't very effective and allowed the tube to slip while trying to flare, I could only do a single flare which worked out okay but I had cut the tubing several times with a small pipe cutter as I experimented with different flaring techniques.

In the end I decided to cut off both transmission lines where I would have a straight shot to the radiator trans cooler fittings (hose barbs) and into the auxiliary transmission cooler. There would also be less stress on the now longer hoses, fewer connections and hose clamps to worry about too. I also removed the quick connect fittings on the transmission and replaced the original o-rings along with new quick connect spring clips.

Lines routed to radiator transmission cooler and then to auxiliary cooler and ATF topped off.

One less leak to worry about!

With the trans cooler lines repaired and oil cooler lines reinstalled I moved on to raising the front diff back into place and buttoned that up, repaired the starter enable relay wire and connector and installed starter, filled with coolant and fresh Valvoline Max Life 5w30 full synthetic, reconnected battery and fired up. Warmed up to check for leaks and bled cooling system then checked gave everything a once over again - hoses, lines and clamps, etc. All in all, everything's been good, nice and quiet and more importantly no mo' leaks. :wings:

 

[Stroverlander]

A few more parts I finally got around to replacing...

Energy Suspension 3.1129G polyurethane transmission mount to replace original stock rubber mount. Again, one of those parts not listed as fitting Astro but cross-referencing pays off, only a few dollars more than an OE replacement and should last quite a bit longer while providing a more solidly mounted transmission.

Replacement was easier and quicker than an oil change - apply penetrating lube to fasteners, support trans, loosen and remove trans mount and subframe hardware, raise transmission to slide out old mount.

Original mount, seen better days.

The urethane mount is a weighty piece compared to the old rubber mount.

Similar to motor mounts, the rubber has warped and shriveled somewhat although not nearly as bad as those.

Installation was the reverse only I applied a decent amount of Super Lube silicone grease to the urethane mount before installing the top plate and the new mounts slotted right into place.

Between the motor mounts and transmission bushing there is no vibration at idle or when revving engine, whereas previously all kinds of vibration and movement would occur. The difference is huge and the van just feels much tighter and solid overall with these mounts.

Next, I moved on to the Energy Suspension 9.9104G polyurethane rear bump stops.

They are listed at 4 1/2" height but closer to 5" overall, stock are approximately 4".

Another simple task, only a few minutes to complete.

A bit bulkier than stock but fit on the perch just fine and no clearance issues.

Really need to do something about those leaf spring brackets...

 

[digitaldelay]

Thanks for the part #'s. I hope to get around to replacing stuff like this someday.

Jason

 

[Stroverlander]

No problem, glad I could help!

 

[Herbie]

Do you feel those bump stops are tall enough? I've been sweating that over on ASV and had been thinking to build up higher perch to use the stock ones. Having done the shock tab relocation, I'm worried about bottoming the shocks on compression. Since I've theoretically raised the rear 4" and the tabs 4", I feel like adding only an extra inch or two to the bumpstop may not be enough...

 

[Stroverlander]

I remember that thread on ASV... were you ever able to determine how much shock travel you're using?

 

[Herbie]

I remember that thread on ASV... were you ever able to determine how much shock travel you're using?

No, the way the boots are molded on my Bilsteins, I can't use the old "zip tie on the shock shaft" trick. Might be that I need to actually find a friend with a fork lift or a ramp and do some static checks...

 

[Buddha.]

Engine mounts, multiple leaks, door bushings, all areas on my blazer that currently need work. Thankfully I'll have more room than you to work I think. I see you still have stock alternator. When mine started howling I replaced it with a unit from a suburban, same max amps but at a lower rpm. It's considerably bigger though so mnaybe it would hit your hood. Certaninly not mandatory but something to think about if yours goes out.

 

[Stroverlander]

That's right, the Bilstein HD boots definitely aren't handy for that.

To try and answer your question...

When doing the shock tab relocation, I did spend quite a bit of time articulating the rear axle and measuring shock lengths and ended up feeling confident (fairly anyway...) of the new shock tab location for my leaf springs/add-a-leaf and shackle setup.

This was one of the links I referenced when measuring: http://www.bajataco.com/travel-measurement.html

I don't have any notes handy from that far back but even heavily loaded and trailer towing, I haven't experienced what I felt was any shock bottoming. I've had those bump stops on the list for a while as I thought they would be a better option than stock and haven't really come across anything much taller. Feel like I'm not much helping that much my Astbro! :ugh:

 

[Stroverlander]

Engine mounts, multiple leaks, door bushings, all areas on my blazer that currently need work. Thankfully I'll have more room than you to work I think. I see you still have stock alternator. When mine started howling I replaced it with a unit from a suburban, same max amps but at a lower rpm. It's considerably bigger though so mnaybe it would hit your hood. Certaninly not mandatory but something to think about if yours goes out.

Hey, yeah I hope you have as much fun as I did! :sombrero:

No need currently (zing!) to upgrade as the original alternator is still going strong!<knock on wood>

I've looked at the 145 amp AD244 to replace the stock 105 amp AD230 and think it's pretty much a direct swap although pulley size may be different if I'm remembering correctly so possibly need a different size serpentine belt.

Good point about the larger housing and hadn't taken that into consideration but thinking about it, I don't think clearance would be an issue, especially with the body lift. Still, may be worthwhile to do a comparison at the auto parts store to be safe. For next to no difference in price, the AD244 seems like a reasonable replacement option and I've been wanting to upgrade the wiring too so that would be an ideal time to do so.

 

[Stroverlander]

Herbie, after looking at my rear shocks, mounts and bump stops a bit more, there's enough thread on the new bump stops to shim them .75" or so if thinking you require additional height. Also, not sure where your lower shock tabs are located on the rear axle but mine are mounted below the centerline of the rear axle if that helps at all.

 

[Herbie]

Thanks, man, that's good info. I think I'll go ahead and order those and then figure out my next steps when I have 'em in-hand. I'll either shim them a bit or make a tube-steel spacer and really bring them up.

My tabs are just below the axle centerline, here's a blurry photo from when they were installed:

 

[Slicky72]

Sorry I didn't have time to skim through your whole thread , do you have a part number for the rear ranchos you installed ? Are you still happy with them?

 

[Stroverlander]

Page one man, page one!

Rancho RS999147 stock length rear shocks with relocated lower shock mounts. They are okay, I explained pretty well (I think) my thoughts behind the purchase and selling my Bilstein HD shocks even though in the end I probably didn't need to.

The tuning adjustment does work and provides a noticeable change in damping characteristics, overall quality not even close to the Bilstein though.

The first rear Rancho shocks I ordered #RS999112 were longer because I wanted to use the stock shock mounts. Unfortunately, these turned out to be the massive 2.75" diameter body, while tough looking didn't fit in the lower mounts unless turned upside down which Rancho doesn't recommend for these shocks. With that plan out the window, I ordered #RS999147 stock length rear shocks (2.18" diameter body), #RS999152 front shocks and heavy-duty lower shock mount brackets from Ruff Stuff.

 

[mapper]

Awesome work Strover. Every time I check your thread I feel like such a neglectful Astro owner I do really need to get it a thread however, it deserves at least that much!

Your van should be lasting a really long time!