Rebuilding after 15 years of storage

[PHOENIX-GER]

Not much progress
We start to customize the shiftlinkeage
But we need this special bolt (german: Gelenkkopfschraube) in metric as i have not the right thread cutting dies in inch
I ordered today as here is no shop which have such material on the shelf.



We use the TH400 linkeage as template



At least the oiltemp sensor for the 4l80e made no problem by installation



we bring both wires - oiltemp transmission and oiltemp engine though this stock passage in the firewall near the steering column



and connect both on their own BIM-04-2 module in the glove box

Now need to find a shop which customize us oillines for the transmission cooler.
We need 2x 90 inches. Nothing seen what was ready to install.

 

[1love]

Very nice!

 

[PHOENIX-GER]

Some Parts arrieved but we had no time this weekend to go on with the truck
It must wait.



We dont care that the glove box is made in Taiwan. We will destroy it for our customizing important only the open/close mechanism on it.

 

[PHOENIX-GER]

You know all that we work on two trucks.
Allways if we wait for parts switch we from one to the other.

A general question:
Is it just me who is too stupid to install these rubber bushings or is it the same for others?



I have a press and still can't get them to fit properly. On the Chevy I have already switched to polyurethane bushings which are much easier to fit.
On the GMC I had to buy these again because I couldn't find any polyurethane for the lower control arms
And of course it didn't work again. Now I'm waiting for polyurethane bushings from energy suspension. The GMC is listed in the description, but when I search for the vehicle type in the catalog, no item is offered. So it remains to be seen whether they will fit.

For those interested in our second project:
While waiting for the spare parts for the Chevy we started to assemble the front axle of the GMC.
But as we couldn't get these stupid bushings into the lower control arms, we had to stop waiting for parts at this point too





Since the parts from the Chevy are here, we can continue with it tomorrow

This way, we never run out of work

 

[PHOENIX-GER]

After a lot of cutting does it fit
I am still not satisfy with the wiring of the appliances, but for space reasons we have to live with it
The metal flap and the lock will be installed at the last part



the shift linkage is ready for a test but since i dropped one of the small adjustment screws... it has to wait again until I have new ones
I searched around an hour and than give it up. When I have new ones it will turn up somewhere.

set screw

 

[1love]

After a lot of cutting does it fit
I am still not satisfy with the wiring of the appliances, but for space reasons we have to live with it
The metal flap and the lock will be installed at the last part

View attachment 934865

the shift linkage is ready for a test but since i dropped one of the small adjustment screws... it has to wait again until I have new ones
I searched around an hour and than give it up. When I have new ones it will turn up somewhere.

set screw

View attachment 934880

View attachment 934866

View attachment 934867

Ich hasse es, wenn ich Schrauben verliere, ich wäre verrückt geworden und hätte gesucht, bis ich sie gefunden hätte, haha. Wie gefällt Ihnen die neue Übertragungsstrecke?

 

[PHOENIX-GER]

Ich hasse es, wenn ich Schrauben verliere, ich wäre verrückt geworden und hätte gesucht, bis ich sie gefunden hätte, haha. Wie gefällt Ihnen die neue Übertragungsstrecke?

Perfectly expressed, only the last sentence doesn't really make sense in German. What did you actually want to say with “How do you like the new transmission line?”<- my translation tool translates it this way. I suspect that my English is also a bit “bumpy” at times

 

[1love]

Perfectly expressed, only the last sentence doesn't really make sense in German. What did you actually want to say with “How do you like the new transmission line?”<- my translation tool translates it this way. I suspect that my English is also a bit “bumpy” at times

Haha I thought I would at least try! I said "How do you like the new transmission link". Your English is good!

 

[PHOENIX-GER]

Haha I thought I would at least try! I said "How do you like the new transmission link". Your English is good!

Thanks. I find my english extremly poor, especially in terms of grammar and pronunciation. When i write, i always check the text several times before posting. I avoid conversations, which is somewhat difficult but possible in my job. It is also always funny when i have to call the dealers to ask about spareparts for our trucks. The grammar in english is really not that difficult compared to german....

I can't say much about the shift linkeage at the moment as i couldn't really test it because of the missing set screw. If it still doesn't display properly in the Dacota instrument the only thing left is the shift sensor, which is also located on the gearbox with the shift linkeage.

 

[PHOENIX-GER]

So small and innocent
To be safe i had ordered 5 ....



Also arrieved the energy suspension bushings which fortunsately fit



So we can go on

 

[1love]

You'll love the new setup!

 

[PHOENIX-GER]

We needed to adjust the sensor also a bit but with it it work now correct
Sorry for the bad quality of pics, made from a video... and the instrument cluster is still with it secure tape on the display





it gone through all gears smooth and directly, no comparison to the spongy switching feel with the cables

For someone facing the same decision, our experience may be of help. But it takes much more skill to make a custom-made gearshift linkage than simply installing the cables.

This was no problem for us as we are machinists. For us, the decision to use the cables was simply a question of time. It takes three times as long to make a linkage than just to install the cables.

 

[PHOENIX-GER]

Now that we have solved the problem with the gearshift, we are in the process of completing the Sierra front axle. There is a hand operation pending and therefore heavy work that requires strength is not possible for the next 6 weeks. The heavy work on the Chevy is all done.

After we were unable to press the lower ball joints into the lower control arm with our tools, we drove to various workshops like a mercedes light truck shop, MAN-Shop, Farmer-Shop... None of them were able to press in the lower ball joints. The right tools were missing everywhere.
In the end, we made the right adapters ourselves on the CNC machine.
Nevertheless, the installation left its mark. Rust protection with repainting is necessary.

Of this disappointing "journey" we lost 3 weekends... just to having this result
Two installed lower control arms, nothing more

 

[PHOENIX-GER]

We couldn`t finished the Kryptonite Front-End on the Sierra before Hand Op. So we start as fast as it was possible in the last week of the year 2024 and had him finally on his own wheels again on the 4th January. Now the frame is in the shop again moveable.





Now the Sierra got a nice comfort-cover and we go on with the Chevy

The fine motor skills are still not full recovered. So the installation of the new electical connector on the Temperature Sensor for the Glowplugmodul was a challange. Thats why we first continue with the Sierra Front-End.

The old connector on the sensor was by disambling broken - he crumbeld to dust the new following had also the new design, so we had to change both ends from the connection



nice they put spare connectors in it but as they was with it we didnt lost one




old and ok but missing his counterpart - i doesn't want use a used connector/sensor unit. These all couldn't be much better than ours.





Not much progress but one thing off our installation list.

 

[PHOENIX-GER]

Wanted go on with the chevy and than this happened on my daily driver.... Volvo XC70



It is the generator belt - so i spent my weekend on this include the brakes as they needed exchange of worn out.

Usually if it can go bad it will do this.
Both disk centerbolts needed drill off



We also found a leaky engine



The new cars have all covered so you see this only if oil drop under your car on the floor or during service when the covers will be removed. Until this weekend our Volvo was always in service by a Volvo Shop. So we dont touched him before...

Looks like he need a little bit more "love and care" if he should stay until the Sierra is ready.

Got now 308 000 km ... the next timingbelt change is next Friday in a shop. We don't do this ourself.

By the way since we change the generatorbelt is the highfrequent noise gone. The Volvo was 4 times of this noise in the volvo shop. They change belts and finally the AC. It was expensive the noise was more silent but still there. They said it is a normal noise i am hearing something what isn't there. Well today i know i was right and i change to another shop with a better custumerservice.

On the chevy we could solve the transmission oilcoolerlines but still in search for an adapter of the oiltempsensor.

As this is all not enough for this weekend: the old tractor Deutz D55 of our farmer in use at our horsestable got a broken cylinderheadgasket. The farmer has a newer Steyr Tractor but dont want that in use from everyone in the stable. We informed him and change tractors as we need a tractor dispose the horse manure. The farmer is in Reha after a stroke. Fortunately he came off with less disability. He ask if we can repair but we have not the time for another project. The Deutz have also a problem on the fuelsystem. It need to be cleaned up. I am not sure if the Deutz is worth the money to repair. He missed a lot of service and everything is worn out.

 

[CARC686]

Wanted go on with the chevy and than this happened on my daily driver.... Volvo XC70

View attachment 939454

It is the generator belt - so i spent my weekend on this include the brakes as they needed exchange of worn out.

Usually if it can go bad it will do this.
Both disk centerbolts needed drill off

View attachment 939455

We also found a leaky engine

View attachment 939456

The new cars have all covered so you see this only if oil drop under your car on the floor or during service when the covers will be removed. Until this weekend our Volvo was always in service by a Volvo Shop. So we dont touched him before...

Looks like he need a little bit more "love and care" if he should stay until the Sierra is ready.

Got now 308 000 km ... the next timingbelt change is next Friday in a shop. We don't do this ourself.

By the way since we change the generatorbelt is the highfrequent noise gone. The Volvo was 4 times of this noise in the volvo shop. They change belts and finally the AC. It was expensive the noise was more silent but still there. They said it is a normal noise i am hearing something what isn't there. Well today i know i was right and i change to another shop with a better custumerservice.

On the chevy we could solve the transmission oilcoolerlines but still in search for an adapter of the oiltempsensor.

As this is all not enough for this weekend: the old tractor Deutz D55 of our farmer in use at our horsestable got a broken cylinderheadgasket. The farmer has a newer Steyr Tractor but dont want that in use from everyone in the stable. We informed him and change tractors as we need a tractor dispose the horse manure. The farmer is in Reha after a stroke. Fortunately he came off with less disability. He ask if we can repair but we have not the time for another project. The Deutz have also a problem on the fuelsystem. It need to be cleaned up. I am not sure if the Deutz is worth the money to repair. He missed a lot of service and everything is worn out.

I've found a good first step to removing rotor set screws is to place the proper 3/8 socket in them and strike it with a dead blow hammer once or twice before removal. They will usually come right out after you shock the corrosion in the threads. On the other hand, if they salt the roads where the vehicle is operated, I would grab the drill first. In either case, I have never replaced the screws. They only exist to keep the rotors from falling off on the assembly line.

 

[PHOENIX-GER]

I've found a good first step to removing rotor set screws is to place the proper 3/8 socket in them and strike it with a dead blow hammer once or twice before removal. They will usually come right out after you shock the corrosion in the threads. On the other hand, if they salt the roads where the vehicle is operated, I would grab the drill first. In either case, I have never replaced the screws. They only exist to keep the rotors from falling off on the assembly line.

This would work if the Torx Screw wasn't already worn out from former replacement in the Volvo Shop. Didnt expect that. A part of just 1 Euro. The Screws should come new with replacement. We was now more than 20 years customer there but about several bad expierence did we change now to another new shop in town. Opened 2 years ago. We got immediatly appointments and repairs. They made service for our C30, repaired the deer accident on the C30 and solved the leaky turbohose (invisible hole) on the XC as daily drivers always at the same day. The volvo shop said the have no appointment free the next 2 weeks...
And they have also a full orderbook.

It exists pros and cons by using the screws. We prefer to use them. So we drill them out carefully, cut new threads and use new original screws. It was just timeconsuming.

 

[Mullaney]

This would work if the Torx Screw wasn't already worn out from former replacement in the Volvo Shop. Didnt expect that. A part of just 1 Euro. The Screws should come new with replacement. We was now more than 20 years customer there but about several bad expierence did we change now to another new shop in town. Opened 2 years ago. We got immediatly appointments and repairs. They made service for our C30, repaired the deer accident on the C30 and solved the leaky turbohose (invisible hole) on the XC as daily drivers always at the same day. The volvo shop said the have no appointment free the next 2 weeks...
And they have also a full orderbook.

It exists pros and cons by using the screws. We prefer to use them. So we drill them out carefully, cut new threads and use new original screws. It was just timeconsuming.

.
That happens over here on the other side of the pond too. Find yourself a good outfit to make repairs, they get "discovered" and they get too big for their britches... When the two or three folks who started the outfit did all the work, it was always done right. Then they grew, hired more people, and quality control just goes away. It's sad.

 

[CARC686]

.
That happens over here on the other side of the pond too. Find yourself a good outfit to make repairs, they get "discovered" and they get too big for their britches... When the two or three folks who started the outfit did all the work, it was always done right. Then they grew, hired more people, and quality control just goes away. It's sad.

That's why I went freelance. Shops always tried to make me do work I shouldn't have been doing. If I managed it, they profited and if I didn't, they got to gloat about how women can't turn wrenches. Expressing an honest understanding of your specific capabilities was viewed as a weakness. Going solo, I didn't have that problem anymore. Ancient history anyway. I guess the moral of the story is to find a solo mechanic who does it because they want to instead of a service writer whose only motive is a commission. I charged half price and made 10 times the money solo. That's a pretty good indicator of how top heavy the industry is.

 

[Mullaney]

That's why I went freelance. Shops always tried to make me do work I shouldn't have been doing. If I managed it, they profited and if I didn't, they got to gloat about how women can't turn wrenches. Expressing an honest understanding of your specific capabilities was viewed as a weakness. Going solo, I didn't have that problem anymore. Ancient history anyway. I guess the moral of the story is to find a solo mechanic who does it because they want to instead of a service writer whose only motive is a commission. I charged half price and made 10 times the money solo. That's a pretty good indicator of how top heavy the industry is.

.
Yes Sir!

That is so true...