2002 2500HD - Solid Axle Tow Rig

Well, since the axle is mostly finished, it's not real exciting. I did grab the wheel bearings because I need to clean them up and get them ready. I've also decided that I'm going to go ahead and buy some new lockouts...the stock ones just don't like to turn and they were going to get replaced anyway. I'm still waiting to get the rotors back from a buddy of mine...can't rush somebody that's doing you a favor! I won't beed them until the truck is ready to move anyway.

Here's a few pictures. I forgot I hadn't actually knocked the knuckle seals in all the way, so I did that. You can see the new style axle tube seals and upper ball joint grease fitting, which you can actually access! Also visible is the shoulder that the wheel will center on that I turned down to allow fitment of a factory GM wheel.

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If all goes as planned....I'll start on this on the 20th and hopefully get it knocked out over the course of that weekend. That means I need to make room in the shop to get the truck in there, add a 220v outlet, borrow a bigger welder, and get my ass to work.

I only have two big things left to get as best I can tell....a steering box and 2" steel wheel spacers for the rear. The front is 72" wms to wms and the rear is 68". That'll look real funmy without spacers!
 
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Pfft...the spacers are getting purchased. It's not worth my time to make them. If I was at my old job, sure, it'd be pretty easy. The one I have now doesn't let you use the equipment...government stuff and all that. I think the pair of them is 320 bucks or so.
 
I got tired of waiting and went ahead ans ordered the steering box, rear wheel spacers, and lockout hubs. I also finally got my rotors back from my buddy who so graciously drilled them to 8x6.5 for me. The lockouts came in today, the steering box will be here next Monday, but I'm not sure when the spacers will get here. I think they're built to order...they should be worth it though! I'm still not entirely sure when I'm going to get on this; I was hoping to get started this coming weekend.

Here's a few pictures so I don't disappoint:

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I can't make a steering box or lockout hubs...so, I gotta wait on those.
 
The steering box finally came today....sweet baby Jesus, that thing is HUGE.


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Got home from work this afternoon and got the rear lift knocked out. One less thing I have to do this weekend. I took tomorrow off, so I have three full days to work on it and I'm hoping I'll be pulling it out of the shop some time on Sunday, but I really have no idea how long it's going to take...we'll see!

First thing to be done in the morning is mounting the new transmission crossmember/radius arm mount. Then the tear down will commence :D

Here's a little action for you guys...you know I can't leave you hangin! Also, noticed an immediate ride improvement with the rear Bilstein 5100s.

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I'll try my best to take as many pictures as I can while in process!
 
Got started this morning, then had to make a hardware store run and some other stuff. We got the front suspension removed, got the front diff pulled out, front driveshaft, torsion bar crossmember, and transmission crossmember were also ditched. Got a few of the mounts cut off the frame, but not much...that's on the agenda for tomorrow. I got the new transmission crossmember/radius arm mount bolted up though!

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Stay tuned for more!
 
How do you like the WFO stuff? I used one of their front D60 truss/coil mounts one time and was very impressed with the fit and finish. Cost was right inline with the rest of the market too.
 
It's pretty awesome. I've used a lot of their stuff in the past on my other two trucks. I always wait to buy big ticket items like this when they're having sales. I bought the solid axle kit over Labor Day weekend and got 20% off and it also put me over spending "X amount" on my credit card in the first three months, so they gave me 50,000 points as an introductory thing and that translates to 500 bucks. On paper, I got 1000 bucks off the kit itself.

They do an awesome job on fit and finish and I bought the King coilovers through them too. Might as well let them do the homework on the valving and spring rates, right?

Today is going to be cutting and grinding...probably the worst part of the whole ordeal, but still not that terrible.
 
Well, today went just as expected. Got quite a bit done, but damn what a bunch of work! I was sorta hoping to have the welding done and have the paint drying overnight...however, I'd rather take my/our time an make sure everything is done right and that there aren't any mishaps with the sawzall or grinder. Everything went smoothly and there were no injuries or brake lines, fuel lines, or radiator hoses cut in the midst of making progress today. I'll start welding frame plates and coilover mounts tomorrow and should have paint drying by tomorrow around noon, hopefully.

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I couldn't just leave the frame and the backs of the frame plates bare, so I shot them with some sealing primer to at least give them a little corrosion protection, but I taped them off so that I hopefully don't burn ALL of it off during welding.
 
I also took some pictures looking back towards the new crossmember. The lighting kinda sucked because it's looking out of the shop door.

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It's so much easier to get to...well...everything under the truck now. That independent front suck-spension crap takes up a lot of room!
 
Or...I could have shut the shop door behind my truck. I barely have time and sometimes almost forget to take pictures, much less apply filters to them. :D
 
Got started mid-morning. Got the frame plates clamped to the frame and test fit them a few times to get them just right so the coilover mounts would sit flush on top of the frame. After that, it was time to bust out the welder. The driver's side also gets a panhard bar bracket...pretty standard stuff, but I'm on the downhill side now. I think I can roll the axle under the truck and do a test fit, cycle the suspension, and see where the bumpstops need to go. That'll be the last thing to get welded on before paint and final assembly!

I'm trying to post pictures, but it's not letting them upload...not sure what the deal is with that.
 
Let's try this again...

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You and me both....I bought the axle in April and I'm ready to hide it under the front of this damn truck! I'm very anxious to see how it rides. I'll probably add hydro assist a little later on too. I may not exactly need it, but it's the best steering stabilizer you can have and the steering box is ported, so what's another 200-300 bucks at this point?

I've got some H2s with 285/70-17s on them with a little tread left. The eventual plan is to run a 295/70-17 and some 17x9 Racelines.
 
Croatan_Kid said:
You and me both....I bought the axle in April and I'm ready to hide it under the front of this damn truck! I'm very anxious to see how it rides. I'll probably add hydro assist a little later on too. I may not exactly need it, but it's the best steering stabilizer you can have and the steering box is ported, so what's another 200-300 bucks at this point?

I've got some H2s with 285/70-17s on them with a little tread left. The eventual plan is to run a 295/70-17 and some 17x9 Racelines.
Click to expand...

I'll take your H2s. It'll be awhile before I can afford the beadlocks. Lol
 
They're going to get put on one of my other trucks :flipoff2:
 
Not really. The frame is boxed up front, plated with 1/4" plates, there's a crossmember in front of the steering box, I have a steering box brace, the motor mounts are almost solid, and then the new transmission crossmember. Seems pretty solid to me. I may add another crossmember under the motor if there's room, but it'll be fine without it.
 
Brace yourselves!

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Ha! See what I did there?! :D

I actually got some shit done this afternoon! Got the new PSC steering box bolted up and for what ot cost, I'm fairly disappointed in PSC for not providing some directions or warnings for installation. You have to bend the hell out of the power steering lines and then spread the coupler on the steering shaft way open just to get it to go together. It was a pain in the ass, but should be worth it. Then I put on the steering box brace, rolled the axle under the truck, put the radius arms on the axle, bolted up the panhard bar, and then tossed the coilovers on for motivation!

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As you can see, the pitman arm is a tight fit, but everything works! I'm planning to have this thing rolling Friday night or Saturday morning. Going to try and put a few miles on it over the weekend. I'm getting a little more excited about it now!
 
Ha, you want the money shot, huh? :D Me too, don't worry! It's killing me to know that I can't work on it this afternoon as it is my mother's birth anniversary...so I'm obligated to do supper and such. I hope she knows what I'm sacrificing :lol:

I should have enough time to swing the axle up and get the bumpstops welded on right after work. Tomorrow I can paint the frame/coilover buckets and while that's tacking up for a second coat I can change the u joint in the front driveshaft, knock the wheel studs back in, and start assembling the outers. It'll be done before we know it!
 
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