PMA4x4
Adventurer
The axles are out of a 1980 fullsize Blazer so there is very little difference. The front extended stock lines are from a 1991 C3500 single rear wheel truck and the extended rear line is from a 1991 Chevy G30 1 ton Van.
Project MULE - Expedition build on a 1991 1500 4x4 Suburban
- Thread starter PMA4x4
- Start date
The axles are out of a 1980 fullsize Blazer so there is very little difference. The front extended stock lines are from a 1991 C3500 single rear wheel truck and the extended rear line is from a 1991 Chevy G30 1 ton Van.
piratexpress1369a
Explorer
powder coat looks good
Renntag
Adventurer
Nice complement of factory parts. Thanks for the info.
I have a 95 G30 extended length van and am curious what axle is under it. Motor (6.5td) is having issues, could be fixed but I have no time or money to fuss with it. Thinking of taking a couple parts (trans/axle) and bidding the rest farewell.
Sent from my SAMSUNG-SGH-I747 using Tapatalk
I have a 95 G30 extended length van and am curious what axle is under it. Motor (6.5td) is having issues, could be fixed but I have no time or money to fuss with it. Thinking of taking a couple parts (trans/axle) and bidding the rest farewell.
Sent from my SAMSUNG-SGH-I747 using Tapatalk
PMA4x4
Adventurer
Ok well here it is in all its glory.
Suspension and axle swap a success! The mule rides even smoother now and sits about 1/2" higher in rear. We will drive it for the next couple of weeks and see where the springs settle. We need it a bit high in rear for when it is loaded it will sit level.
List of all that was done during this project
10 Bolt front with 4.56s and Auburn LSD
12 bolt rear with 4.56s, Auburn LSD and Yukon shafts
All new Tire rod ends, bearing and seals front & rear
All new brakes front and rear.
Weld in frame steering plate kit
ORD Steering brace
4" raised steering arm.
Tough Country 3" HD front springs
New 3/4 ton springs in rear
2.5" rear block in rear (for now, then will chenge springs or add flip kit)
Bilstein 5100s
ORD front shackle kit
Greasable poly front bushing kit
Greasable poly sway bar bushing kit
Sway bar drop brackets
Extended (but still OEM) brake lines
New pre-bent brake lines on 12 bolt.
Suspension and axle swap a success! The mule rides even smoother now and sits about 1/2" higher in rear. We will drive it for the next couple of weeks and see where the springs settle. We need it a bit high in rear for when it is loaded it will sit level.
List of all that was done during this project
10 Bolt front with 4.56s and Auburn LSD
12 bolt rear with 4.56s, Auburn LSD and Yukon shafts
All new Tire rod ends, bearing and seals front & rear
All new brakes front and rear.
Weld in frame steering plate kit
ORD Steering brace
4" raised steering arm.
Tough Country 3" HD front springs
New 3/4 ton springs in rear
2.5" rear block in rear (for now, then will chenge springs or add flip kit)
Bilstein 5100s
ORD front shackle kit
Greasable poly front bushing kit
Greasable poly sway bar bushing kit
Sway bar drop brackets
Extended (but still OEM) brake lines
New pre-bent brake lines on 12 bolt.
PMA4x4
Adventurer
I figured its time I actually start using the gauges that have been sitting around for the last year. This is just a temporary mount and wiring location until I get the center console built.
Next on things to do is solder in a dip switch block so I can re-program the DRAC so my speedo isnt 20mph off at highway speed.
Next on things to do is solder in a dip switch block so I can re-program the DRAC so my speedo isnt 20mph off at highway speed.
Renntag
Adventurer
Ah ha ha. Figuratively speaking "Gear change". I meant, since you have gauges, you probably aren't going to change your plan and go with a different gauge solution.
Gear change = change of plans. I guess that wasn't the best expression to use given the subject matter and recent updates.
Gear change = change of plans. I guess that wasn't the best expression to use given the subject matter and recent updates.
PMA4x4
Adventurer
So we got back from our 10 day trip into Utah. It actually was a couple days in Payson for a friends jeep event I was sponsoring then off to Utah until the next friday and went onto the Overland Expo. We had a blast doing this and never got burnt out on camping, we just wanted to keep going.
We only had one major hiccup and that was the steering gearbox came loose from the frame! It came on so slowly that it wasn't until the end of the day when we camped I had realized I was having to make almost 1/2 rotation steering corrections to stay straight. The next morning I got underneath and had Bridget turn the wheel and there it was CLANK CLANK CLANK! lost 2 bolts and the other 2 were loose. I also found one of the sway bar brackets has all the nuts and washers missing as well. I knew we went down some nasty washboard roads but dang! I tighten the remaining two bolts up and then its was a 63 mile jaunt to the nearest hardware store and there we are doing repairs in the parking lot of Ace hardware in Blanding Utah.
One thing we did quickly find out is that the Mule is severely under powered. Once we got back I started researching. Even before the trip I was thinking of a 7.4 Vortec swap. I had then remembered how much torque the Tuned Port Injection system did. Let the research begin! I found with some basic parts and barely mild upgrades you can easily 400lbs of torque and not sacrifice economy.
Last Friday I decided to officially start hunting for a 96-2002. Then it starts. A guy had posted a '97 vortec pulled when running a couple weeks ago with 130k on it for $300 complete. After some horse trading I brought it home Saturday morning.
I then decided to find a OEM harness for cheap (if it existed). Came across a 85-89 TPI harness for $40 complete no ECM. I go there and find that all the ends have been tagged even the that the connctor had busted apart and left bare wires. He mentions he found the ECM for it and said here take it. He then says I have the intake manifold for it, its your if you want it. At this time I am thinkinh ok I'll take the intake even though I will be replacing it for the vortec TPI one. I follow him back to a parts shed that would make any chevy guy cry. used and (old stock) new parts eveyrwhere. All mostly performance parts just laying around wanting to be save and used again. Anyways, he proceeds to hand me all the parts for a complete Tuned Port Injection setup and not just the intake manifold. Injectors, rails everything.
The guy - "I was planning on putting it Craigslist for like $200 but if you want you can have it".
Me - "uhh, sure."
So the tally for all the awesomness over the weekend.
One complete 1997 Vortec with roller cams and L31 heads (possible 4 bolt main)
85-89 TPI harness out of a camaro/TA
85-89 TPI parts ECM MAF sensor type (not as sensitive to changes like others)
85-89 TPI manifold complete (just disassembled)
Total cost $315
It looks like hell but it actually lays out pretty clean and nice.
We only had one major hiccup and that was the steering gearbox came loose from the frame! It came on so slowly that it wasn't until the end of the day when we camped I had realized I was having to make almost 1/2 rotation steering corrections to stay straight. The next morning I got underneath and had Bridget turn the wheel and there it was CLANK CLANK CLANK! lost 2 bolts and the other 2 were loose. I also found one of the sway bar brackets has all the nuts and washers missing as well. I knew we went down some nasty washboard roads but dang! I tighten the remaining two bolts up and then its was a 63 mile jaunt to the nearest hardware store and there we are doing repairs in the parking lot of Ace hardware in Blanding Utah.
One thing we did quickly find out is that the Mule is severely under powered. Once we got back I started researching. Even before the trip I was thinking of a 7.4 Vortec swap. I had then remembered how much torque the Tuned Port Injection system did. Let the research begin! I found with some basic parts and barely mild upgrades you can easily 400lbs of torque and not sacrifice economy.
Last Friday I decided to officially start hunting for a 96-2002. Then it starts. A guy had posted a '97 vortec pulled when running a couple weeks ago with 130k on it for $300 complete. After some horse trading I brought it home Saturday morning.
I then decided to find a OEM harness for cheap (if it existed). Came across a 85-89 TPI harness for $40 complete no ECM. I go there and find that all the ends have been tagged even the that the connctor had busted apart and left bare wires. He mentions he found the ECM for it and said here take it. He then says I have the intake manifold for it, its your if you want it. At this time I am thinkinh ok I'll take the intake even though I will be replacing it for the vortec TPI one. I follow him back to a parts shed that would make any chevy guy cry. used and (old stock) new parts eveyrwhere. All mostly performance parts just laying around wanting to be save and used again. Anyways, he proceeds to hand me all the parts for a complete Tuned Port Injection setup and not just the intake manifold. Injectors, rails everything.
The guy - "I was planning on putting it Craigslist for like $200 but if you want you can have it".
Me - "uhh, sure."
So the tally for all the awesomness over the weekend.
One complete 1997 Vortec with roller cams and L31 heads (possible 4 bolt main)
85-89 TPI harness out of a camaro/TA
85-89 TPI parts ECM MAF sensor type (not as sensitive to changes like others)
85-89 TPI manifold complete (just disassembled)
Total cost $315
It looks like hell but it actually lays out pretty clean and nice.
Renntag
Adventurer
Awesome stuff.
Crazy that so many bolts came loose. I guess that is a good argument to add some blue loctite to the threads and then field check it regularly. Really glad nothing was damaged.
You mentioned the need for more power, I havent done any serious work with my '91 V2500 but already have possession of it's new power plant. I am going with a second gen, p-pump, 12 valve cummins. The down side is clearly the additional weight up front, but I think the reliability and torque in stock trim will far out weigh this issue. The cost is higher with a cummins swap. Your port injected small block solution is definitely simple and cost effective.
Looking forward to seeing some pictures from the adventure. :sombrero:
Crazy that so many bolts came loose. I guess that is a good argument to add some blue loctite to the threads and then field check it regularly. Really glad nothing was damaged.
You mentioned the need for more power, I havent done any serious work with my '91 V2500 but already have possession of it's new power plant. I am going with a second gen, p-pump, 12 valve cummins. The down side is clearly the additional weight up front, but I think the reliability and torque in stock trim will far out weigh this issue. The cost is higher with a cummins swap. Your port injected small block solution is definitely simple and cost effective.
Looking forward to seeing some pictures from the adventure. :sombrero:
Larry
Bigassgas Explorer
It was great to finally meet you at the Expo Rob!
Bummer about the steering box and sway bar bits coming loose. I’d find that guy that just bolted all that stuff together and kick him in the shins! LOL
WOW! You can’t beat that price for the engine and TPI goodies. That is indeed the deal of the day, especially if you go the TPI Vortec head specific intake! That should hold you over for a while but I still feel in the long run you will find the small block, even with TPI treatment, does not have enough nut to propel these large rigs around the way you would hope especially after you bolt in much heavier axles and bolt on gizmos and gear. Those little engines work so hard to propel something that heavy they end up drinking more fuel than their big block brothers. There is no replacement for displacement in the gasoline side of the world. A sequential injected Vortec 7.4L or 8.1L swap is very easy but the cost of admission certainly wouldn't be anywhere near what you stole these small block bits for. Nice score!
Looking forward to watching the swaperoo
Bummer about the steering box and sway bar bits coming loose. I’d find that guy that just bolted all that stuff together and kick him in the shins! LOL
WOW! You can’t beat that price for the engine and TPI goodies. That is indeed the deal of the day, especially if you go the TPI Vortec head specific intake! That should hold you over for a while but I still feel in the long run you will find the small block, even with TPI treatment, does not have enough nut to propel these large rigs around the way you would hope especially after you bolt in much heavier axles and bolt on gizmos and gear. Those little engines work so hard to propel something that heavy they end up drinking more fuel than their big block brothers. There is no replacement for displacement in the gasoline side of the world. A sequential injected Vortec 7.4L or 8.1L swap is very easy but the cost of admission certainly wouldn't be anywhere near what you stole these small block bits for. Nice score!
Looking forward to watching the swaperoo
PMA4x4
Adventurer
Finally nice to me with you too Larry!
I think part of the gearbox issues was the weld in frame kit. I don't think that was entirely flush with the frame so there was some "spongyness" in there and I think it just worked loose but its fixed.
The TPI project will definitely be interesting for the results. I had came across a few articles with dyno tests showing just over 400lb of torque with Vortec heads, the TPI with the 24lb injectors (2lbs over stock) and a GMMP ZZ4 roller cam. The magic combo is really the TPI and heads All low and mid range. I ran a basic desktop dyno finding 293hp and 432lb tq. Using something like the Weiand stealth ram or a new LT1 intake is more for top end loosing power for pulling with the shorter runners.
I think part of the gearbox issues was the weld in frame kit. I don't think that was entirely flush with the frame so there was some "spongyness" in there and I think it just worked loose but its fixed.
The TPI project will definitely be interesting for the results. I had came across a few articles with dyno tests showing just over 400lb of torque with Vortec heads, the TPI with the 24lb injectors (2lbs over stock) and a GMMP ZZ4 roller cam. The magic combo is really the TPI and heads All low and mid range. I ran a basic desktop dyno finding 293hp and 432lb tq. Using something like the Weiand stealth ram or a new LT1 intake is more for top end loosing power for pulling with the shorter runners.
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piratexpress1369a
Explorer
nice score