Update time again. I installed the new 225amp Powermaster alternator to go along with the new heavy duty cabling, and it performs very well. I also installed new upper and lower radiator hoses, added new heater hoses (thankfully because the fitting on the original was brittle and snapped easily) flushed the radiator and added new DexCool (though it seems I only got 12 quarts of the old stuff out as that's all that went back in - so I guess I did a 3/4 flush). No real sexy pics, but here are a few:
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I also installed new Spicer 5-795X Triple Sealed Solid U-Joints in all four spots. The clunk I had when shifting is now completely gone and the driveline feels tighter - so I guess 180K miles and 15 years is nearing the upper limit of the OEM u-joint lifecycle - not too shappy GM. No pics - nothing to see here, move right along.
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Sticking with the driveline theme, I was hearing a faint rotating noise from the rear of my Av. At first I was thinking ARB locker as it is nearing it's initial service check, but then I remembered the last time I heard that faint noise coming from the front it ended up being a wheel bearing letting go on the way home from San Diego. My rear wheel bearing are the factory originals. Combining those two thoughts with a nagging thought I've had regarding the strength of the stock rear axles given the amount of weight on the truck combined with the 4.88 gears, locker, and 35" tires - I had been giving serious thought to stronger axles. Another thing is the stock differential cover. It is thin stamped steel. ARB makes a very strong one that is shaped to also help disperse force and add strength to the overall rearend. I tried to put one of these on when I first had the locker and gears done (I have a custom track bar so space isn't an issue), but the locker bolts were hitting the inside - so I stayed with my stock one. This time however, I was curious so I called ARB Tech and they told me they make them that way on purpose and to just grind out the excess to make it fit. Um, OK - seems like they would just make them big enough to fit everything rather than everyone having to grind them. When I did my gears in late October, I also had a master bearing kit installed - so everything inside of the pumpkin is fresh. On this go around, the Av got: New ARB diff cover, G2 hardened cold rolled alloy steel axles, new wheel bearings, fresh oil, and the locker checked out. Ready to roll.
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My buddy who designed and built the suspension wasn't real happy that I had installed Spohn Performance tubular rear control arms. So, while he was revalving my shocks to account for the increased weight, he made new ones and installed them. While I was happy with the Spohn's (I only ever did one trip with them), the ones he built are downright beefy and stout.