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BBYHUMR 06 Re-build

BBYHUMR

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Looking forward to the next build status!
You and me both!!

Stereo is still in process currently, box and amp rack are finished up and ready for carpeting & trim, door speakers are installed on driver side with sound deadening to match.
Last rotation I spent a solid 3 weeks in Kerrville Tx dealing with all the flooding then the fam and I went to Colorado for a little pre-school start 4 day get away. I'm currently in Albuquerque working on some hail and collision claims, should be home end of next week and hopefully be able to make some progress at that time.
 

BBYHUMR

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Small update. Tinkered with the radio bezel a bit today. Not extremely happy with how it came out so likely will be revising the bracket into something my ocd can tolerate but it’s in and powers up with a quick test.
iPad is jailbroken so when it sees voltage it wakes up & unlocks, when it sees no voltage it goes into sleep mode
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Still need to run some 0 gauge wiring to the amp location and finish up the wiring adapter from the factory amplifier (on order). Carpet and padding should arrive tomorrow and Wednesday so hopefully can get the box and amp rack carpeted later this week.
 

BBYHUMR

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Bit of an update that will likely upset some people on here but to each their own. Keep in mind I will likely be using this as a radio and gps only. The option of having WiFi is nice but will likely rarely be used.
****Note*****
I do not condone the use of a tablet while driving.
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Still need to run wiring for the rear amps but those are assembled and ready for power, ground, and signal on the amp rack.
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Stiiiiiiiiil waiting (nearly a month now) on the connector to arrive to allow direct plug & play into the Monsoon wiring harness to prevent cutting wires.
Also got the subwoofer enclosure carpeted & padded but ran out of spray adhesive to finish off the edges. The two ports still need finishing trim installed as well but like I said, ran out of spray adhesive soooo….
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Also finally got around to replacing the shift boot which has long been needing it.
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I’m a bit torn to the silver surround around the shift boot and if I should treat it to the same black I did with the radio. Always thought the silver was a bit out of place on these all black interiors. Thoughts? Don’t mind the mess, it’s a work in progress.
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BBYHUMR

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Stereo is in and making some good noise. Components speakers installed in all doors and a-pillars. Still need to finish up the port beauty panel but otherwise everything is installed and tuned. All doors and the rear floor have been sound deadened, I will likely pull the seats and carpet out eventually and do the floor and possibly the ceiling.
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BBYHUMR

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Some updates!

I had ordered a steering rack clamp bushing a while back and had just never gotten around to doing it. While “listening” to training modules I decided I would throw it in and what a huge difference it made. The alignment is still off but at least now the Hummer doesn’t wander while driving straight.
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Clamp bushing was certainly needed. I know I should probably replace the other steering rack bushings and I will, however I also found a torn inner tie rod boot while doing the clamp so I will likely do everything at once.

Had safelite come out to replace the windshield which was very needed but since the truck wasn’t registered it was kind of on the back burner as far as priorities go. Amazing how one little thing like that made such a huge difference.
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Unfortunately in the process the technician broke the re-glued tabs on both windshield moldings so now I am looking for either a replacement set or I may just finagle some in a 3d print. He also had to take off the wiper cowl to do the windshield which was broken in a previous hail storm so also looking for a new cowl panel as well.

After the windshield replacement I threw some 50% over the entire windshield and some 20% as a visor strip
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Chose to do 50% since technically windshield tint is frowned upon by the law enforcement, but 50% is difficult to tell it’s even there from the outside but it makes a huge difference on the inside.

Also went down to the local Ace hardware store and bought a can of Freon. I’ve recharged systems before when I was a tech but I kept thinking I was doing something wrong since nothing would display on the gauge. Turns out the system was just completely empty which means there is likely a leak somewhere. Luckily the add-a-can I got has some dye in it so eventually I’ll take a look at where the Freon is going, but for now it blows nice and cool (need a second can to completely charge).

Also FINALLY got the rig registered so I can now legally drive it around! Woo!

Also ordered a replacement oem looking brush guard off Walmart surprisingly enough. Not sure what the quality will be but after looking for 3+ months at junkyards and either finding very few or the yard wanting $800+ I decided to go with an aftermarket option. Should arrive tomorrow and will likely be installed this weekend.
 
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BBYHUMR

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Brush guard came in today, and honestly, not bad. It got a bit scratched up in shipping but no worse than what it will eventually deal with.
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No instructions included with the dozen or so pieces, but I mean…it’s a grill guard…. Its not neurosurgery. After roughly 45 minutes I had it all assembled and installed with hand tools. The girl’s nose job is all but complete!
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I will eventually buy a light bar for the middle bar (already pre-drilled) for a bit extra light when driving our back rods which are flooded with hogs & deer for most of the year.

Yesterday afternoon I picked up a new 3d printer to start messing with. First thing (after some toys for my daughter) will likely be some replacement a-pillar moldings unless I can find a headlight/foglight file to fill the area around the grill/bumper.
 

BBYHUMR

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Small update on the rig.

Been driving it a bit more regularly and correcting things as they pop up. Ive probably only driven it about 2k miles since I got it but it’s been a good rig for around town.

Just recently had one of my blend door motors go out so I’ll be throwing in a new one after the holidays.

On a previous post I mentioned I had a torn inner tie rod boot, and had some down time this past week on my week off so we got to work. As normal my helper was plugging along with me for most of the process
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Yes, I went with red boots, no there was no reasoning behind it, just saw them at the right price and clicked add to cart.

Also did a “driveway alignment” after replacing the boots. No it’s not perfect by any means and I’m sure once it gets to the alignment shop there will be other adjustments needed but for now, it tracks straight and I pulled the 1/4 turn of the steering wheel out of it. Ended up adjusting both sides 3/4” (measuring from outer lip of wheel) to straighten up the steering wheel.
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I drove out to Haskel (small town an hour west) to pick up some used 18” wheels on what I thought was a great deal. Looked them over the best I could in the back of the guys truck and pulled the trigger on them. Once I got them home I realized I got scammed….

Wheels were covered in mud when I went to look at them. Once I got them home and cleaned up some I found the wheel stud openings were hollowed out, on every single wheel.
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It is what it is, there are always risks when buying on marketplace and this is the first bad experience I’ve had on it.

With every defeat comes great victory though!

I have been looking for a set of 35” tires off and on for a year or so. They’re not high on the priority list though as my current wheels still hold air and rotate in the right direction however I found a deal I couldn’t pass up.
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Got 7 of these Toyo Open Country 315/60R20 for a grand total of $200. Pictures don’t do them justice but they all measure out around 9/32 which is a little under half life on them. They all have the caliche cancer tires get around here but overall they’ll do just fine. I’ll use 5 for the Hummer once I find a set of wheels and sell off the other two and make back some of my money.

That’s all for now. I’ll hopefully get things rolling again once storm season kicks back off
 
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BBYHUMR

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Minor update. Picked up a set of wheels the other day when I was in Dallas for my Pennsylvania licensing test. Wheels are dirty but in decent shape, some scratches and bumps but nothing that can’t be overlooked or repaired easily if I choose to.
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Didn’t take any pictures but being the cheap ass I am after many different attempt versions I finally found a version that worked to get off the old worn out tires using the Hummer and a 2x6, instead of paying the local tire shop $20 per tire to dismount the old tires. Basically you just up and run up on top of the bead of the tire repeatedly until it breaks loose.
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After a few choice words I was able to get the TPMS sensor swapped over from my factory wheels and one of the replacement tires mounted using some crowbars and some slip solution. Overall I’m happy with the size although I think 18’s would be a better look but when working on a budget we can’t always have exactly what we want. Truck should sit about an inch and a half higher than it does currently with the torsion bar cranked, old wheels measured out to around a 32” if I remember right.
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BBYHUMR

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Well finally after some delay I got the wheels and tires put on. Makes a world of difference in appearance with the 35’s filling the wheel well a bit better. Although I still think 18’s would be a better wheel fit I’m happy with the outcome.
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After
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Changed a bunch of fluids over the weekend, engine oil came out with some clumps but better than the original oil change. However after draining the oil I only got about 3 quarts out of the pan and filter, which means in the roughly 2000 miles I’ve driven since I did the first oil change I lost almost 3 quarts of oil without a drop underneath. Sounds like valve seals are shot or possibly the rings.
Also found a heavy seep coming from the front diff driveshaft seal, just one more thing to add to the list of repairs necessary, but for now I’ll just keep an eye on the fluid levels and continue topping off as necessary. Once the motor comes out this summer I’ll be doing a reseal job on the front diff
 

BBYHUMR

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hey on the bright side, that's a lot of nice rust prevention underneath lol
lol i guess that's one way to look at it.

luckily i have a truck i am able to borrow for a week but after that it's going to be a bit of a cluster for getting around.

i already have a line on a motor but it's up in oklahoma out of a wrecked silverado and i have to pull it so trying to figure out the logistics of that and the misc other pieces i need were a bit stressful lastnight but it'll work out...let the shopping spree begin....anyone have a line on an alpha manifold?
 

BBYHUMR

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Well, I had to back out of the Silverado. There are no exhaust manifolds to be found anywhere that will fit without some serious modification (BFH). After running the numbers on the swap and misc pieces needed to do it, plus the transmission rebuild to swap the shaft and other necessary components I realized my pricing was getting pretty steep for a motor with 200k on it. On a whim I decided to look for other options that didn’t involve a 200k mile V8 motor and $3k worth of other bits and pieces to make it work on top of the price of the swap, plus the headache of trying to find a non-existent manifold.

Enter Copart. I found a 2008 Alpha that was rear ended and appears to have a pretty destroyed frame and rear axle which doesn’t bother my needs at all. Truck has 80k miles on it and is completely stock from the looks of it, excluding some running boards and wheels/tires. The unit looks to be in great shape and I’ll be able to sell off a lot of the unneeded parts from it to make back some of the purchase price. Seats are nearly immaculate as is the carpet which I’ll likely be throwing into my H3 to replace the driver seat and carpet which is showing some wear. I’ll be picking it up mid next week out of Kansas.
 

crwalkerasla

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364
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Corinth, MS
Well finally after some delay I got the wheels and tires put on. Makes a world of difference in appearance with the 35’s filling the wheel well a bit better. Although I still think 18’s would be a better wheel fit I’m happy with the outcome.
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Changed a bunch of fluids over the weekend, engine oil came out with some clumps but better than the original oil change. However after draining the oil I only got about 3 quarts out of the pan and filter, which means in the roughly 2000 miles I’ve driven since I did the first oil change I lost almost 3 quarts of oil without a drop underneath. Sounds like valve seals are shot or possibly the rings.
Also found a heavy seep coming from the front diff driveshaft seal, just one more thing to add to the list of repairs necessary, but for now I’ll just keep an eye on the fluid levels and continue topping off as necessary. Once the motor comes out this summer I’ll be doing a reseal job on the front diff
Check out the valve cover/PCV condition. This got clogged up in my 2006/I5 and cost me my original engine and complicated my engine rebuild. Didn't realize it until after the fact.
 

crwalkerasla

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364
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Corinth, MS
If doing a V8 swap in an '06, be sure to check your computer compatibility. I ran into issues when researching it for my rig, and didn't want to run 2 computers. I hear that it's possible I. The '06, but for me no shops locally could/would tackle it.
 

BBYHUMR

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Check out the valve cover/PCV condition. This got clogged up in my 2006/I5 and cost me my original engine and complicated my engine rebuild. Didn't realize it until after the fact.
I'm sure knowing what the oil looked like when i purchased it it's very possible i had some clogging issues, however I was getting on the highway and put my foot a bit too heavy on the floor to merge in front of a big rig which is when the rod blew. It was my own fault pushing a 230k mile motor hard when i knew it was on its last legs. It is what it is unfortunately but it'll work out in the long run. I'll end up selling off the transmission and transfer case to someone who wants them since they're still good and sell the motor of to a scrap metal company or someone interested in a core.

If doing a V8 swap in an '06, be sure to check your computer compatibility. I ran into issues when researching it for my rig, and didn't want to run 2 computers. I hear that it's possible I. The '06, but for me no shops locally could/would tackle it.

My i5 computer wont work with the v8 which is why i purchased a full alpha (besides trying to find a non-existent exhaust manifold). I'll be using the pcm/tcm from it and i'm currently working with Jamie out of Canada to configure all the wiring necessary for the transition. My end goal is to not run a dual computer system and have the vehicle function as close to factory as possible. I'll be handling the full swap and wiring myself, luckily I have mechanical background and have done a considerable amount of wiring in the past, just need to have a trail to follow on the wiring from someone who knows what it takes to lessen whatever future issues may arise. I'm sure there will be some issues that pop up like any swap, but it's just a matter of diagnosing them one by one and being patient through it.
 

crwalkerasla

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364
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Corinth, MS
Understood. From what I recall, GM changed the computers in '08. After that they were V8 compatible. The '06 needed the original PCM to talk to the '06 BCM for the truck interior components (this is another discussion entirely if you want the odometer to keep working.)
 

BBYHUMR

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Understood. From what I recall, GM changed the computers in '08. After that they were V8 compatible. The '06 needed the original PCM to talk to the '06 BCM for the truck interior components (this is another discussion entirely if you want the odometer to keep working.)
From what i've found from previous research from threads and discussions with other owners over the past couple years who have done it my understanding is it's possible to make the pcm and bcm play nicely with each other but it requires re pinning the bcm to pcm connector and running a number of new feeds to the cabin of the truck for the obd2 port along with some other misc wiring to avoid use of the original pcm. So essentially you're still using the original BCM for the instrument cluster and items like cruise to function as they did with the i5 but it requires some in depth wiring and programming to make everything get along between the '06 BCM and '08+ pcm/tcm. I believe you would need to continue use of the original pcm if you were wanting to essentially run the engine pcm/tcm as a stand alone unit for more adjustability and tuning capability for the engine and transmission, which I know a lot of people prefer since it requires less complicated wiring.

That is correct though, after 08 the electronics are nearly plug and play, if i recall correctly there are only like a half dozen wires that need modification to work with the 4g equipment, however I never really dove too far into my research on this process as it did not apply to my '06.

i'll know more about what's involved once i get a line from Jamie which should be toward the end of the week.
 

BBYHUMR

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Productive day overall. Got the engine and transmission cracked apart and everything disconnected. Just waiting on the engine hoist to arrive tomorrow to pull the engine and transmission/transfer case out then comes the long fun process of cleaning all the oil from the frame rails and underside of the truck. I’m sure I forgot a ground strap or bolt somewhere but I need to be able to move the engine around a bit to confirm what all is still connected.
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Decided to pull the radiator and condenser as well to make the pull out easier, condenser has a leak anyways so I’ll be using the Alpha condenser but I didn’t want to damage the new radiator I just put in.

Also, not to be that guy but who’s looking for an undamaged i5 power steering reservoir. No low ballers I kNoW wHaT I gOt lol
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Let’s start the bidding at one million dollars lol. Seriously though, if someone is looking I’ll be glad to ship.
 

BBYHUMR

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Two updates for one!

Day 2 in the books.
Very unproductive day, spent the majority of it waiting on fedex to deliver the engine hoist just to find they only delivered one of the two boxes for it.
I chose to drop the transmission & differential cross members and get to work cleaning them up but didn’t get much else done.

Day 3
Again spent the majority of the day waiting for FedEx to deliver the other half of the engine hoist. While waiting I decided to lay down some tarps in the garage to keep the spillage to a minimum for clean up.
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FedEx finally showed up around 430 with the other box necessary for the hoist. After a quick assembly and some curse words the drivetrain was removed by roughly 630.
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Unfortunately that’s about all I was able to get done today due to waiting on FedEx for about 3/4 of the day.

Hopefully more tomorrow. We’re expecting big hail here in town so I’m not sure how much I’ll get done but updates will come as available.
 

BBYHUMR

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Day 3.5 or 4 or something like that.

Spent an abnormal amount of time at the rental car center waiting for the person in front of me get a vehicle. For some reason they thought they didn’t need to bring a license or credit card with them to get a rental car and couldn’t understand why the counter person wouldn’t give them a car without it…..

Once I finally got to the house my goal was to get the Hummer in the garage since we’re expecting tennis ball size hail here tonight & tomorrow. Luckily the neighbor got home just as I started pushing the H3 into the garage with a series of tow straps to pull it in. I had planned on spending roughly an hour getting it in the garage (slight incline) but only took about 30 seconds with 4 people so I got to work on cleaning up the engine bay with a can of foaming degreaser and simple green.
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Spent a few hours working on getting things cleaned up between the foam, simple green, a pressure washer, and a couple bristle brushes. Came out much better!
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The differential was pitch black and the steering rack was completely covered in about 3/4” of grease and dirt. Front crossmember required some scraping with a paint scraper to get the caked on gunk off before hitting it with the degreaser and pressure washer.

All in all it was a productive roughly half day (only got to work for about a total of 3 hours.

Got the girl to fit in the garage with the engine, trans, hoist and misc other stuff while still leaving room in the other side of the garage for the 4Runner.
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The Alpha “should” arrive tomorrow. Been trying to get communication from the transport company I decided to go with but it’s been very hit and miss unfortunately. I’ll focus on getting the steering bushings and diff bushings replaced tomorrow while waiting on the wrecker, then start taking apart the old i5 harness to modify the Alpha harness with.

I’ll be flying out to upstate New York on Sunday for the start of catastrophe season so it’s my last few days of getting work done before going silent for 3 weeks. Once I get back my motor mounts should be on hand and I will have had time to research the wiring notes from Jamie so hopefully I’ll be able to make good progress on my next week off
 
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