barry G's 1996 gmc 4x4 5spd

[barry G]

power steering cooler line

 

a chore I wanted to get to, with spare subaru turbo oil lines.

 

 

this is the old setup. the exit side of power steering box up to the cooler.

I remember seeing this a lot, even before 1988. No barbs, wimpy swollen rubber and cheap clamps.

Always had a wet spot at a minimum.

I worked at a quick lube 20 something years ago. Young gm trucks coming in almost always had the wet spot..right at the box and hose.

I figured they all had a cheap setup.

Glad to get to this my way..

 

 

as odds had it, fit right in. The fitting was already in my compilation for something else on a subaru.

Straight shot out now. Much stronger.

Edited May 21, 2017 by barry G

[barry G]

the turbo line power steering cooler line swap..

I had to add something, as i did not use thread tape.

seeing the factory connect at just 3 threads and a tiny grommet holding it..

I will surely stick to this much deeper new connection.

 

I added lucas stopleak for power steering. It does wonders for this exacting problem.

I am guessing first try with it gets it.. very slow weepy spot.

 

in two days since install and some miles added, about 1/8th cup. Still over the cold line in the pump stick.

 

frustrating stuff. No real excuse to leak.

 

my new brakes did the same thing.

I learned it to be resonant frequency.

a tesla like physics subject.(I am not kidding). I'll give it a few days..maybe a week.

Edited May 23, 2017 by barry G

[barry G]

oil change!

 

this is very exciting!

 

more than 6000 miles since last august.

Mobil 1.

no bearing materials, metallic speckles of any kind.

photos can do the talking.

 

my locale in maine has gone to 21 below and 94 above since last august.

 

looking back at the old oil (see what I did there?)

filter cleaned up , back together

Aim it at the sun to get a peak through a clean .15 micron.

dirty shot. before clean.

dirty shot. This is the magnet after >6000 miles.

next oil change @ 368,561 miles

Edited May 24, 2017 by barry G

[barry G]

1990 gmc cracked frame

 

 

 

maine craigslist.

 

 

I like to share these as i find them. I have not seen a 12 footer from 1996 onward yet..or any year of the gmt400 for that matter.

This is a first.

 

I noticed a flex between the two rivets, and no factory weld.

 

I usually find needs at rear shock mounts, cross sills, tire crossmember..

laminate on rear tails...rear left.

 

But I have not found a hip broken in the last years of gmt 400.

my own is welded by factory.

would love to see one if it is out there.

 

this is an "old school" crack. Something you could find from 1973 -?

 

I am inspired to laminate the bottom of my 96 in the same spot, simple flat stock, even though there is no problems.

Edited June 6, 2017 by barry G

[barry G]

a lot of talk.

veterans after getting helped.

 

My neighbor, he has the longest rides in my truck.. I have no need to travel 222 miles.

Disabled viet nam vet, the sickness gets an 8000 dollar shot. I take him to the V.A. hospital.

In my own mysterious death imminent.. I was there for several years with hardly a stomach function. I came back on my own. Two 30 cup pots of coffee, about 5 gallons of fluid a day.

 

I am nearly in the big and tall category even after being runted into a bean pole. I know what lucky is.

The smaller boned people.. they got an incredible advantage sometimes.

At 75 yrs old.. maybe 5 foot 4. That is one tough old guy. Do ponder what he outlived, and to keep a vivid memory...

Viet nam from day one..seeing it to the end.

 

disabled vet and stuck.. no transportation..?

If you needed a ride from my rural place.. I'd most likely give one.

I break even on the fuel. Same low income as any one else disabled.

I am a DAV member. Something I caught onto right away..

how much can you continue to give? that is the goal.

 

 

 

Not much fun for the long ride. I got a chuckle going into a roundabout.

His generation, pontiacs and hemis..

 

this old truck is not exactly slow. Top of second is just hitting 60.. but that is 5500 rpm or so. I hardly go there.

Edited June 15, 2017 by barry G

[barry G]

summer fuel mileage

 

17.36mpg.

 

finally got a very accurate double top off. fill before and fill when back home, measure miles etc.

242 miles.

 

this truck sailed into 21 and even 24 when I first got it.. I did not like that.

Now with a/c on all the time, it just might be the a/c..

 

seems a bit hefty, at 5100 pounds to be climbing into the 20s mpg.

 

this angers subarus and hondas and mr.beachys and...

 

my dad's 2016 went past 20 on its first longer highway ride.

impressive.

the new trucks are designed for several things..deactivated cylinders etc.

the old iron has no real excuse for going into hypermiler.

 

it is rather funny.

 

 

[barry G]

Tow day

 

 

I had not towed much since all the extras were done.

Kept the a/c on, of course went over the uhaul speed limit..

 

this was the test for the welding I had done. Just like a toy getting hauled.. a bit over 3000 pounds.

a/c robs some power, well worth it.

and brakes...could use something beefier when towing.

just have to plan ahead for stops, hope there is no emergency.

 

the brake system is near new. Front and back.

Edited July 10, 2017 by barry G

[barry G]

decided to throw some new shocks at it.

 

 

it is noticable. Ride was good before changing.

 

 

the old ones seem to be very old.

I had a real problem with bolts not accepting any wrench.

finally got them out and swapped them for less than 12mm (7/16ths) american grade 8.

 

tightened it down real good. any slop in the metal sleeve will go unnoticed.

 

in machining, circumference change by .4 inch is gigantic. that is what I am calling the new monroes compared to the old.

much larger diameter.

55 bucks, the cheap ones.

 

odometer is now very close to 364k.

 

this is my most relaxed year with this. Inspected yet again today..needs nothing. It seems i moved the cab as door and cab corner, all the seams are tighter.

I won the frame with the welds apparently. Very straight truck.

A/C is flawless, everything is working.

 

I was even complimented the other day. Caught me off guard.

it is a nice old truck, imperfections included.

Edited September 3, 2017 by barry G

[barry G]

hanger brace

 

looking over my brothers 2003, and I saw this bracket by factory that has been a peeve of mine for decades. my 1996 has the dangliing hanger and no extra brace filling predrilled gm spots. The 70s and 80s had a lot of the same weirdness.

 

So I went to home depot and grabbed some 3/16ths angle iron.

 

I 'll call this part 1.

not much to notice, except reverse does not want to hop.

Will be doing some more trimming, one more bolt.. then off to the other side symmetrically.

will be done this weekend.

bolts are class 10.9

 

the other trigger for this extra was looking over my neighbors 1995 gmc. Same color and body as mine. The last of TBI and no real alternator control. Frame is gone in this area where I added the brace...rear hangers are through the bed. Frame is simply gone.

my own frame is in excellent condition, less than one year newer..with more than twice the miles, at 363k now.

 

get it while the going is good.

maybe I'll get a 1 ton half ton out of this after all.

 

the first thing to notice, no hop in reverse. It is indeed adding some integrity already.

Not sure what else it is adding to yet. Not done with bolts and installing.

will share completion.

Edited September 13, 2017 by barry G

[barry G]

hanger steel pt2

 

 

added the other side, made angle cuts.

I like what this did. Not much to notice but I had a grumbling bounce at certain take offs, and backing up. All that is done, and feeling sturdy.

one more bolt up front, and a triangle tacked in up front for final closure.

I am convinced this is a 3/4 and half ton factory hybrid. that manual trans is very stout.

 

summary of strengthening

 

• bed removed, all cross sills replaced or doubled (all steel is bigger than factory)
• frame attacked with hammer to find needs. Welded as necessary.. the tails and shockmount
• new shocks all the way around
• poly cab mounts
• poly sway bar endlinks. new endlinks
• poly transmission mount
• custom rockers, stainless sheet and square tubing over the working original.
• custom cab corners, stainless and regular
• LT rated tread, S speed rating, 3450 load range E
• the two hanger extras (first spotted as factory on my brothers 2003.. glad I saw those)

 

that is about all for the strengthening.

I love driving this around.

forgot to list

• balkamp hefty ubolts
• 900 pound hellwig leaf helpers
• tire crossmember frankenstein (I like the strange shape of it, and kept the rusty one as a template to build on)

 

 

truck is about 100-150 static steel heavier.. after installing that number is different on a scale.

Approx 5100 pounds wet now.

this one starts off at 4770 as factory.

 

Still quick, and sounds fabulous..confident. Almost power strokish with an extra hard tranny whine.

The air bypass kicks in every shift, sounds like a blow off whistling a low frequency.

 

for future thinking.. the old axles may need to be fatter, or change rear end entirely to the next model up. 12-14 bolt.

it has a cold end wobble most of my tenbolts gain as years and miles accrue.. but it dials in every time, if it even has to.

Smooth runner.

Edited September 15, 2017 by barry G

[barry G]

extra hanger steel finished

 

 

 

 

the extra steel turned out to be very clever. Great ride, no bouncing. I finished it with 7/16ths grade 8 at the pointy front, both sides.

the angle iron also showed me the frame is as straight as the day it left the factory.

21 years gone by, bouncing around.

these trucks all bounced with the manuals, until a hefty 3/4 or 1 ton.. and even then..

 

 

Took the boat for a tow, and a ride.

 

changed shock bolts all to factory sizing, one needs a tighter torque.. but doing very good.

I declare this one better than new...and I am serious.

 

it may be 3/4 ton territory by now. Damn close.

 

a funny followup..

my brother has a 2003, xcab (little 4 door), 5.3L.

My dad has the 2016 xcab...the new 5.3L.

the old 96 is the 305 manual.

a freakin stiff tank in comparison, hauling the same boat. No squat. Plenty of suspension, hardly uncomfotable. I do admit.. I got more work in steel and mounts than the other two trucks.

I thought it was funny. I was adding stuff to stop bouncing on certain terrain..and here is the 2 other generations of truck doing it worse than my old one never did. Maybe they got too many doors that open.

Maybe I demand too much..

 

One thing that is awesome is the tow mode and overall power in the 2016. That is a very nice truck to haul the boat.

if I was a shallow journalist, could have had some fun with this.

 

on the same steep boat ramp.. my own has a feel to tug 20 times more the weight in 4 lo granny gear...with not even a hint of shudders.

the 2003 burns rubber,

and the 2016 does something just right.

 

for braking, the 2016 is the champ.. the transmission even gains engine braking.

the 2003 has some peculiar noises.. but power is good. Going into gear after towing a little bit, its as if the convertor is all lit up going too active. Bangs stuff around going into gear.

 

the 1996 has a clutch feel of just getting started after some miles. Very confident.

the 2016 feels the heaviest, becuase it is. That one fact makes it the winner. the weight of the tug vehicle compared to what is behind it.

the 96 is the lightest with a gvwr of just 6200. The minimum in factory 4x4.. due to the manual trans.

 

no long term rides yet, the 96 is the only one that has had the boat halfway around the state and coastline hills.

I think it would win for stamina.. but that 2016 is being very smart so far...

Edited September 17, 2017 by barry G

[barry G]

a real bad cat

 

just ordered this fab pro version.

 

I get a 420 cat code within a mile of resetting codes.

it may have been this forum that delayed my will to go high flow.

Watching live data I verified it. the cat is seriously bad.

I don't care how, or what someone else might theorize.. the exhaust is almost eye watering sometimes.

 

 

I also believe I went beyond their weight theories. My wimpy half ton is in a realm of its own welded world.

the first 420 code kicked on after load range E tires. Frame work had been done some time before then. The truck is more than 200 pounds static over factory.. that is before starting it up and laying on the torque.

 

 

So.. to clear this trucks only code, I went with a magnaflow clone, 200cpi.

this will get it out of the weight limits and increase flow.

I am looking forward to some fuel mileage... like 5-10 mpg.

that was the final straw. In fog my fuel mileage doubles.. it must be killing the cat while the air is foggy.

I have had this exact problem in this locale..but those engines were carbed. Same outcome.

new lesson for me.

 

injection/carbed doesn't matter. the live data is very nice to verify however.

may have it in by the weekend.

I do like sharing sound clips with the other custom builds.. will get that in too.

it already sounds bigger than it isn't. Being a welder, I'll leave the "why" explanation on that wavelength of hard earnings.

 

the better cat should be interesting. Not annoying by law, just bigger.

 

 

and a delayed item (pun).. that will be arriving as well.

random run on with the wipers, and it stops the washer from working while randomly running on. then suddenly it all works like it supposed to.

 

$13.26 on ebay

Edited September 29, 2017 by barry G

[barry G]

codes clear

 

I have had a p0420 code for a year. It kicked on after load range E tires.. must have been just enough extra weight to trigger.

 

 

 

I found the old cat was gutted.. to m y surprise. what is weirder than that? it wqas still eye watering poisonous. the exhaust odor was horrifying. I could knock people over with exhaust odor.

 

 

added a high flow cat, and it needed to be lengthened to take up space.. I used stainless 439 for its hight temp/corrosion resistance.

 

gained 8mpg solid.. could me more. I only have 50 miles on it.

Codes clear.

Truck needs nothing.

 

sounds good. Very mature and legal and won't bother anybody. Smells like anew truck. nice to see some water droplets gaining 18 feet out to the back.

Edited October 6, 2017 by barry G

[barry G]

cat final

 

 

it was a day in april.. a puff of grey, something different happened right then and there.

I am thinking I gutted the cat just by driving. we do hit 25 below or so, when no one is looking.

my fuel dropped off some, but i did not care.

 

whatever the reason, several days after new cat install I had a goofy cold start today, after some rain.

something dialed in at the cold idle, throttle up and down as if hunting.. like an old carb. Woofing that vortec sound... taking a new breath.

it levelled off to a beefier runtime.

I am wondering if I took it out of a non-existent limp mode.

the ect is up by about 5, the intake air temp was up 30 over the temp outside.

live data shows all four o2 sensors very active and dynamical...

 

anyway. I guess patience is what dials it in.

no codes on the ecm, CEL light installed.

I used the original, it may have a resistance value the ecm needs.

6 bulbs shy of a full LED swap, and it is for good reasons.

[barry G]

door corner

 

I have fat cab corners from 364k miles of the north. it may be 1/4 inch thick at the door corners. I cracked the passenger side  edge, and eventually broke it right off this year. I grabbed some staionless 304, bent it up into some folds. Cut a square out of the door corner up to the trim to hide one seam.

welded it in.

 

 

my fuel is over doubled to the new cat. I should have known better. the early obd2 can feed fuel.. but the ramp to go with it is not there.

I gained power, a nice sound, faster warmups..

the over doubled mileage is almost embarrassing. low to mid range is huge. you know my truck is coming in the quiet places..

 

I did record a video for high flow cat and flowmaster being together. I guess owners pay a lot to get the whole system done. I do it myself.

my dad is running the 1000 dollar borla on his 2016 for example.

I do not go that far.

will see if it recorded correctly and share.

Upon opening my mig weld crate, found some leftover stainless 439 from cat install.

a tail tip works with an air gap. This one has an 1/8th inch. Quick scrub to see if there is any shine to come back out. Tacked 4 spots.. away it goes.

Edited October 16, 2017 by barry G
spelling