94 Suburban 1 Ton Conversion, Need Some Advice!

turboshelby · August 13, 2011

I recently picked up a 1994 1 ton chevy for $400 (!) and need to transfer the suspension and running gear (minus engine) into my 94 1/2 ton suburban. Looking at the two trucks side by side, I know I have my work cut out, but it needs to be done. I work at a GM dealership and have access to any special tools/equipment I may need. I was wondering if anyone has done this conversion before, and what will need to be fabricated. I know that a-arms, torsion bars, and front diff give give me some hell and was wondering if anyone knew what problems I will be running into. The suburban is used as a 1-ton, and I dont think it will hold up much longer. I use it for towing very heavy loads, plowing 2ft+ of snow, ect, and I cannot afford to find a 3/4 ton and the 1-ton pickup is beyond repair. I have the general knowledge, skills, and time to do this conversion, but as I said I really just want to know if anyone has done this and what I will be getting myself into. Will I have to cut and re-weld mounts for torsion bars, a-arms, etc? Will my brake booster and master handle the 1-ton brakes? What stuff (if any) will be straight bolt-on? This project will be starting in the very near future, as I would like to have it done before snow season gets here. Any help would would be GREATLY appreciated, and I would be happy to post pics and how-to's if anyone else needs the info.

turboshelby · August 13, 2011

Please, nobody suggest fixing the pickup or using its frame instead, as I just won't. I need my suburban and cannot have it down for more than a few days, and I am fully aware that the 1/2 ton frame is not as beefy as the 1-ton, but do not have the time for something that involved. I need the passenger space and the 1-ton capacity in one package! For my application, this conversion just needs to happen!

CapitalTruck · August 13, 2011

I don't see it working out.

turboshelby · August 13, 2011

Well that's not very optimistic ;)

ybsane · August 13, 2011

" I use it for towing very heavy loads, plowing 2ft+ of snow, ect, and I cannot afford to find a 3/4 ton and the 1-ton pickup is beyond repair. I have the general knowledge, skills, and time to do this conversion"

You quote yourself as saying you have the time to do this,but you can only have it down for a few days... .?

With everything you are doing with it already I say swap out the axels and transfer case and inspect your frame the best you can, it would not hurt to box the frame is some locations to prevent cracking e.g. near the power steering box,front end near the plow attachment,transmission/transfer case, and rear axel.

Make sure the transmission will bolt up to the transfer case and there is good chance you can probably take the whole assembly out to attach. Since you have the donor truck start measuring everything right away, all attachment points for the front axel assembly,rear axel,drive shaft lengths,etc. No sense in ripping everything apart till you do all of that first and feel real confident about length,width and attachment into the suburban.

Good luck....Rob

turboshelby · August 13, 2011

Good advice! This evening I am cutting off the frame from the 1-ton from the torsion bar mounts forward. This will allow me to have it in the shop with my suburban, and I will be able to take better measurments and be able to easily cut and re use brackets if necessary. Only thing I can see for sure right now is the upper control arms are spaced a little farther apart, but the diff, trans, t-case, and shocks all seem to mount the same. I will take more precise mesurements once I have the frame in the shop. I have the time to dink aroud with the old frame and one-ton stuff, I just need to have everything in order so my suburban isnt down more than a weekend at a time, it needs to be at least drivable during the week. I figure I will have a weekend in the front end, assuming I have things ready and know what to do. One day for the swap, one day to account for all the BS I wasnt expecting I know it's doable, I was just REALLY hoping someone has done it and could key me in on what exactly is different and how it was solved. As I said though, if anyone else needs the info, this conversion is happening somehow or another and I will be happy to keep records of what had to change and how. Will def beef up the frame near plow mounts, etc as it is pretty abused in the winter time. Thank you for the advice so far.

ybsane · August 13, 2011

Good advice! This evening I am cutting off the frame from the 1-ton from the torsion bar mounts forward. This will allow me to have it in the shop with my suburban, and I will be able to take better measurments and be able to easily cut and re use brackets if necessary. Only thing I can see for sure right now is the upper control arms are spaced a little farther apart, but the diff, trans, t-case, and shocks all seem to mount the same. I will take more precise mesurements once I have the frame in the shop. I have the time to dink aroud with the old frame and one-ton stuff, I just need to have everything in order so my suburban isnt down more than a weekend at a time, it needs to be at least drivable during the week. I figure I will have a weekend in the front end, assuming I have things ready and know what to do. One day for the swap, one day to account for all the BS I wasnt expecting I know it's doable, I was just REALLY hoping someone has done it and could key me in on what exactly is different and how it was solved. As I said though, if anyone else needs the info, this conversion is happening somehow or another and I will be happy to keep records of what had to change and how. Will def beef up the frame near plow mounts, etc as it is pretty abused in the winter time. Thank you for the advice so far.

Sorry I can't help much with the front end swap. Got very good at the solid front axel swaps in the 80's. Dana 60 in the front with a Full Floater 14-bolt in the back was very easy to do in 2-days back than.

Rob

turboshelby · August 13, 2011

Understandable. The completely custom-from-scratch SOA and 3/4ton swap on to my old Jeep J-10 took only 1 day. I am hopeful that with care measurement that this can be similar, but not expecting it.

eqras · January 22, 2012

I'd really think about checking into the front straight axle with leaf springs conversion.

djmercer1 · January 22, 2012

I recently picked up a 1994 1 ton chevy for $400 (!) and need to transfer the suspension and running gear (minus engine) into my 94 1/2 ton suburban. Looking at the two trucks side by side, I know I have my work cut out, but it needs to be done. I work at a GM dealership and have access to any special tools/equipment I may need. I was wondering if anyone has done this conversion before, and what will need to be fabricated. I know that a-arms, torsion bars, and front diff give give me some hell and was wondering if anyone knew what problems I will be running into. The suburban is used as a 1-ton, and I dont think it will hold up much longer. I use it for towing very heavy loads, plowing 2ft+ of snow, ect, and I cannot afford to find a 3/4 ton and the 1-ton pickup is beyond repair. I have the general knowledge, skills, and time to do this conversion, but as I said I really just want to know if anyone has done this and what I will be getting myself into. Will I have to cut and re-weld mounts for torsion bars, a-arms, etc? Will my brake booster and master handle the 1-ton brakes? What stuff (if any) will be straight bolt-on? This project will be starting in the very near future, as I would like to have it done before snow season gets here. Any help would would be GREATLY appreciated, and I would be happy to post pics and how-to's if anyone else needs the info.

adding the springs and axles wont make the burb a heavier truck-->it will only guarentee that the abuse is going to hit the frame instead of the suspension it is hitting now. your best bet is to get a set of 1 ton running gear/frame and swap over the burb body.

in any event, the suspension swap will be tricky and require careful measurments due to the deeper frame and some customized brackets, but not hard. i think your hope of 1-2 days may be optimisitc though, i would say 4-5 days...

gmtech4 · January 23, 2012

aug to january jump in posts ,i think he is done or stopped the swap ,,

end this thread

Silverado4x4 · January 23, 2012

aug to january jump in posts ,i think he is done or stopped the swap ,,

end this thread

Yeah really, I love when people dig up a old post some 2-3 years old sometimes and then add a reply. I think posts older then a year should be deleted.