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1999 Chevy Tahoe 2 Door Refresh

Discussion in 'Quitters' Club' started by Norcal69, Aug 29, 2024.

  1. Jan 23, 2025
    3b a runnin

    3b a runnin Active Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    virginia
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    Where I live in the rust belt, most 99's have been gone for years. And oddly enough the frames are more likely to rust away than the body. Recently sold a 2004 Silverado to the junk yard for scrap price because the frame was in horrible condition.
     
  2. Jan 23, 2025
    Mr_Vaughan

    Mr_Vaughan Member

    Central City, NE
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    how has the semi float 14 bolt treated you? i've never thought much of them, as i just generally dislike sime floaters, but the idea of an extra beefy 6 lug axle is tempting.
     
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  3. Jan 23, 2025
    Norcal69

    Norcal69 Out of the box thinker 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    The 14 bolt semifloat is from a heavy half ton model truck, often referred to as a W/T model.
    It is a big upgrade over the factory 10 bolt chevy. The 9.5" ring gear 14 bolt uses 33 spline axles and 3/4 ton drum brakes.
    I have not had any issues with it, it just has roughly 200K miles on it since installed.... and I might as well rebuild it while I am doing everything else.
     
  4. Jan 27, 2025
    Norcal69

    Norcal69 Out of the box thinker 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    Transfer case input swap/rebuild.
    I picked up a NP241 rebuild kit from Trans Parts Warehouse, a local shop that ships rebuild kits nationwide.
    The Yukon transfer case, previously connected to an automatic transmission, has a 27 spline input shaft. The old Tahoe transfer case contained a 32 spline input shaft that is necessary for mating to the Nv4500 manual transmission.
    The 32 spline input from the Tahoe.

    [​IMG]

    The input shaft swap and subsequent rebuild of the Yukon transfer case went smooth. All of the bearings in the transfer case were replaced, including the needle bearings in the input shaft and front output support on the back of the case. Those bearing in particular were a real PITA to get out!
    The Yukon transfer case did not really need a rebuild, but since it was apart and the rebuild kit was only $86, friends and family price, I wanted it to be new just like the rest of the drive train.


    [​IMG]


    Something interesting....
    The Yukon came from a cable company fleet. It had been used for some sort of cable connection vehicle as it had racks in the back with all kinds of communications connectors and splicing necessities. It came with highway tires and likley never saw any 4wd use.
    We purchased the Yukon with 71k miles on it about 10 yrs ago. It was at auction and was running poorly due to the common OE fuel injector failure. I installed new updated injectors and it became our "extra" vehicle. I only know of one time that we put the Yukon in to 4wd during that 10 years and that was only for a short distance when my CJ was stuck in the mud with a broken front driveshaft.
    The range selector eccentric in the Yukon transfer case shows no signs of wear... unlike the eccentric in my Tahoe which had allot of 4wLow use.
    I would be willing to bet that this transfer case has only been used in 4wd once or twice it's entire life. The wear pads on the range forks showed no signs of wear either.


    [​IMG]
     
  5. Jan 30, 2025
    Norcal69

    Norcal69 Out of the box thinker 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    Not a whole lot of progress the last few days, but the transfer case is done.
    When I tore down the old case from the Tahoe I immediately found the rear output bearing retainer ring was broken.

    [​IMG]


    While looking for the correct replacement retainer ring I discovered that this is a very common failure. Apparently manual transmission models are more prone to this breakage than automatics.
    My guess is the increased torque/shift harshness from the manual transmission. :shrug:
    I found a permanent fix offered by Torque King 4X4. The retainer ring is replaced with a 2 piece shaft collar that has been bored out from one side to fit the shaft OD. A small retainer ring width is retained on the opposite side. This fits into the retainer ring groove on the output shaft.


    [​IMG]

    The transfer case is now complete and ready for a clear coat of engine enamel.
    Hopefully the clear coat will prevent mud, grease, oil and sawdust from accumulating and make cleaning easier.
    Getting the tc installed and crossmember in will be a big step forward.
     
  6. Jan 30, 2025
    Norcal69

    Norcal69 Out of the box thinker 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    Back when I was cleaning and painting the front frame, the transmission cross member received the same cleaning/rust removing and paint treatment.
    A generous coat of semi gloss Rustoleum was sprayed through a Harbor freight HVLP Gun. I sprayed this without thinning the paint.... and still managed to get a nice big run. :sneak:
    New convoluted tubing retainers were installed on the cross member.

    [​IMG]

    The transfer case and it's brand new transmission/transfer case mount.
    This is not going to be a show vehicle whatsoever as I plan to daily drive the Tahoe when completed. I would like to thing that the future oil change technicians will treat it with a higher level of care when they see how clean it is underneath.


    [​IMG]
     
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  7. Feb 3, 2025
    Norcal69

    Norcal69 Out of the box thinker 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    Slowly coming together!
    It's extremely satisfying to install clean parts.

    [​IMG]


    Before installing the transfer case and crossmember I was able to snake the exhaust system out in one piece.
    This is a Flowmaster 3" catback system that was installed in 2004. From day one I was disappointed with the drone and volume level of this muffler. Unfortunately there wasn't any other bolt on systems available for a 2 door Tahoe. Cracked and rusted out years ago, I am glad to see the muffler go.
    I will be reusing the inlet pipe and tailpipe from the system. Long term plans will be to build a new system from the converters back.
    It appears that at some point the over axle section was rubbing on the frame crossmember to the point that it wore a hole in the pipe. Adjustments will be made to prevent that from happening again.

    [​IMG]

    [​IMG]
     
  8. Feb 4, 2025
    Norcal69

    Norcal69 Out of the box thinker 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    Started on the inner fender insulation last night.
    This is the same Noico sound deadner that I have used in other places, just with black foil rather than silver.
    I went with black foil to keep the stock appearance under the hood. Much of the inner fenders are covered by the battery tray, air box, ECM, air injection pump, ABS and fuse box.
    Black foil tape was used to seal the seams.
    The passenger side is completed, it barley makes a sound when a wrench is dropped on it.


    [​IMG]
     
  9. Feb 4, 2025
    Mr_Vaughan

    Mr_Vaughan Member

    Central City, NE
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    i'd love to see what it sounds like after this is all done, i can imagine it'll probably rival a new tahoe. almost makes me want some sound deadening for a few of my projects.
     
  10. Feb 4, 2025
    Norcal69

    Norcal69 Out of the box thinker 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    I am also looking at a spray on wheel well liner for both the front and the rear.
    There is a long ways to go, but when it is complete it may actually be quieter inside than a new Tahoe. Eventually the roof, door skins, quarters, ect.... will all be sound deadened and some insulated.
    Some PDR will need to take place before all of that is done.
     
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  11. Feb 5, 2025
    Norcal69

    Norcal69 Out of the box thinker 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    With both fender wells fully sound deadened I turned my attention to a project I have been putting off for a while.
    The lower steering column bushing/bearing/plastic housing.... whatever you call it, it's junk after all these years. I think GM has had an issue with lower steering column rattles for the last 30 years..... This also serves as the housing for the EVO sensor which is no longer necessary.
    The ultimate solution is an offering from Wolff Engineering which replaces the stock garbage with an aluminum housing and 4 set screw locking bearing.

    [​IMG]


    Not cheap, but worth every penny!
    This eliminates all of the slop at the firewall joint and takes care of the phantom rattles when hitting pot holes or rr tracks.


    [​IMG]


    Two upgrades in one picture.
    New clutch master cylinder from LUK.
    New brake master cylinder from a NBS Chevy truck. I installed the brake master cylinder a while back but did not post about it. The NBS master cylinder is a popular upgrade for 88-99, OBS, Chevy trucks.


    [​IMG]
     
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  12. Feb 5, 2025
    Norcal69

    Norcal69 Out of the box thinker 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    Prepping to install the front inner fenders and core support.
    I find that projects go back together smoother when you have clean bolts.
    Only guys that live alone will understand.... :beer:
    Yes, I added the jet dry for a spot free rinse.

    [​IMG]
     
  13. Feb 5, 2025
    Jw60

    Jw60 New Member 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Trails end,...
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    I have the same dishwasher :susp:
     
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  14. Feb 6, 2025
    Norcal69

    Norcal69 Out of the box thinker 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    You can scroll up a couple posts and see the previous condition of the cat back exhaust system.
    I welded up the rubbed hole in the tailpipe and dented the area while it was still hot. A fine wire wheel cleaned all of the tubing up nice.
    The front rusty section is factory mild steel pipe and the rear is mandrel bent aluminized tube tube from Flowmaster.
    My plan is to paint the system with high temperature silver ceramic paint.
    Introducing the exhaust pipe to their newest friend, the biggest muffler that Magnaflow makes.... :rofl:
    The Magnaflow is a straight through design and should provide a nice rumble but not be annoying like the Flowmaster.


    [​IMG]
     
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  15. Feb 6, 2025
    Stakebed

    Stakebed Member

    Lake Co....
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    I agree Kyle. I'm so over Flowmonster's hollow sound and Magnaflow makes quieter muffs. I also like Hooker's Aerochamber muffs.

    Remember, no muff too tough. We dive at five.
     
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  16. Feb 11, 2025 at 9:22 AM
    Norcal69

    Norcal69 Out of the box thinker 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    Getting closer to seeing big progress!
    I was not thrilled with the threads on the frame-battery-engine ground bolt. With the alternator requiring a dedicated ground it was only going to make things more complicated.
    My solution was to ditch the 2 thread thick frame hole/tapered bolt for a ground stud. I ground the plating off the bolt head and paint off the frame before burning this bolt on all the way around.
    This was so satisfying, the body-frame-cylinder head ground location got the same treatment!


    [​IMG]


    Saturday morning was spent harvesting a very clean, undamaged core support at my local Pick N pull.
    The original plan was to use the core support from the Yukon, but it proved to be more damaged than I thought. With as much work as I am putting into this project I could not bring myself to cut a corner on a $62 part that is easily sourced from a wrecking yard. Of course a few other random essential tidbits that will make the project cleaner were scored at the yard too.
    New core support sitting on later model silicone body mounts from S&B. The bolts supplied with the body mounts, while specific spec for later model GM trucks, work perfect on the Tahoe frame.


    [​IMG]
     
  17. Feb 11, 2025 at 10:36 AM
    Bubblehead617

    Bubblehead617 New Member

    Ocean Park, WA
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    I totally understand what yer doin! The dishwasher does a fantastic job of cleaning parts. I used our for mo'cycle parts. Also used the oven to cure whatever painted parts would fit. Connie drew the line at me doin fiberglass body repair for the race bikes in the dining room :rolleyes:.
     
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  18. Feb 12, 2025 at 9:25 AM
    Norcal69

    Norcal69 Out of the box thinker 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    The liquid AC line on the Tahoe was missing all of the insulation, the Yukon line however was in great shape. It was wrapped in foil tape to preserve the insulation going forward.
    Picked up a bag of AC O rings for the entire system and ordered a AC flush tool/canister to clean the evaporator core out.
    Test fit the AC core and installed the high ambient temp orifice tube, a little known GM option to improve AC operation.
    There are still lots of under hood parts to get cleaned up before install... battery tray, evap system, air pump, washer res... ect.
    Installing the inner fenderwells felt like major progress last night, everything is fitting up nice.


    [​IMG]
     
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  19. Feb 13, 2025 at 10:58 AM
    Norcal69

    Norcal69 Out of the box thinker 2025 Sponsor 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    There is a fair amount of front end assembly that needs to take place in a specific order, so a portion of the evening was spent figuring out order of assembly.
    I mocked up a factory style auxillary cooling fan. These fans came factory on higher end models for enhanced AC performance and HD models for enhanced cooling system performance.


    [​IMG]

    While at the wrecking yard to source the core support, I pulled a front end wiring harness from another rig. This harness is from a LS model truck with factory composite headlights and has provisions for the factory corner market lights, something that my old brittle/crusty harness did not have.
    15 years ago I added a factory temperature and compass mirror to the Tahoe. The harness for the temp sensor was zip tied along the headlight harness.
    I tore down the new headlight harness to integrate the wiring for the mirror in to it for a cleaner factory look.
    While the harness is apart I will be adding wiring for the electric fan and 4 hi mod, low beams stay on when high beams are turned on.
    The end result should be a clean one run wiring harness.
    Fan harness and relay on the left is from Old Air Products. It is a clean universal setup that covers everything but the trigger source. I have not yet made a decision how the fan will be triggered, my application is only for low speed/stoplight waiting AC performance.


    [​IMG]
     
  20. Feb 13, 2025 at 12:03 PM
    3b a runnin

    3b a runnin Active Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    virginia
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    Gonna add hidden wiring for a front and rear dashcam while doing the harness?
     
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