H2 160K Overhaul

[jarek m]

Long story short our 03 H2 lately started to show sings of fatigue, finally last weekend following a friend in blue down GS Parkway at unsafe speeds to say the least we melted the selector fork in the TC. 4 locked is not fun on the black top. Since there is nothing nearly as original looking on the market as an Hummer SUV time to give some love after our H2 has given so much to us.

I did this to many times with my LR not to believe it's not going to snowball on us.

Short list:

-Transfer case rebuild
-Drive shafts rebuild
-Front diff re-seal
-CV joints
-Tie rod ends
-Driver front drive hub
-Repack rear wheel bearings
-Transmission chip
-Conserve under carriage
-Ignition coils
-Injectors
-HVAC control head
-Trace horn problem
-Assortment of upholstery problems
-Update the stereo


The truck is up and dis-assembly has begun and it's a mess under there!!!

http://i32.photobucket.com/albums/d45/Basia678/misc/002-7.jpg

http://i32.photobucket.com/albums/d45/Basia678/misc/003-2.jpg

http://i32.photobucket.com/albums/d45/Basia678/misc/004-2.jpg

http://i32.photobucket.com/albums/d45/Basia678/misc/005-3.jpg





Dealer quote "anything between 2.5k and 6k" can you say Ballpark figure LOL!!!









:D

[HumminNBoatin']

Looks like you got a good bit of work to be doing. And why would you drive on dry pavement in 4hi lock???

I have done it in emergency situations like once i broke a 1/2 shaft and did not have a spare. I had to drive it home for 55 miles.

[jarek m]

Looks like you got a good bit of work to be doing. And why would you drive on dry pavement in 4hi lock???

I have done it in emergency situations like once i broke a 1/2 shaft and did not have a spare. I had to drive it home for 55 miles.

TC locked it's self, no selector fork, can't unlock.


Little progress today, TC out and drive shafts.


That's where those vibes where from, balance weights missing.

http://i32.photobucket.com/albums/d45/Basia678/misc/008-1.jpg

http://i32.photobucket.com/albums/d45/Basia678/misc/009-2.jpg


Water contamination.

http://i32.photobucket.com/albums/d45/Basia678/misc/010-2.jpg


http://i32.photobucket.com/albums/d45/Basia678/misc/012-1.jpg


Wasn't supposed to unbolt the adapter :mad:

http://i32.photobucket.com/albums/d45/Basia678/misc/007-2.jpg


:popcorn:

[Intercooled]

I assume your doing all this work yourself ?

[jarek m]

Did my hubcap oil pan give me away?:shhh: Lol, yes it's happening in my garage.

[jarek m]

More progress today...

http://i32.photobucket.com/albums/d45/Basia678/H2/002.jpg

Man this bolts are on there!
http://i32.photobucket.com/albums/d45/Basia678/H2/004.jpg

Driver side needed some persuasion to come off.
http://i32.photobucket.com/albums/d45/Basia678/H2/005.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/006.jpg

Both sides are gone. Any one need a trail spare?
http://i32.photobucket.com/albums/d45/Basia678/H2/007.jpg

Got to keep things labeled.
http://i32.photobucket.com/albums/d45/Basia678/H2/003.jpg

[Intercooled]

Kudos to you. I wish I had the know how to do that kind of work myself. I'm sure you'll save a ton of money, but you'll endure the frustration.

[jarek m]

Kudos to you. I wish I had the know how to do that kind of work myself. I'm sure you'll save a ton of money, but you'll endure the frustration.


Anybody can do it Haynes RM got step by step. And so far I used like only three different sockets. This one haven't been that bad so far, actually nothing compering to my other one.

http://i32.photobucket.com/albums/d45/Basia678/misc/008-2.jpg

Oooooooooo that's right I'm the enemy! LOL!!:D

[jarek m]

Come to think about it, why all the bolts so far on this truck are metric? Feels like I'm working on my Rover.

[jarek m]

Diff is out
http://i32.photobucket.com/albums/d45/Basia678/H2/014.jpg


Cross member rusted to ****!
http://i32.photobucket.com/albums/d45/Basia678/H2/010.jpg


http://i32.photobucket.com/albums/d45/Basia678/H2/011.jpg


Got to research upgrading to a Elocker.
http://i32.photobucket.com/albums/d45/Basia678/H2/012.jpg

[jarek m]

What is that?

http://i32.photobucket.com/albums/d45/Basia678/H2/012-1.jpg

[Hellz]

it looks like.....

you will need a bigger socket!

not sure if it is metric tho..

[VegasGuy]

I'd say this thread automatically qualifies jarek m far beyond the misnomer, "Hummer Novice."

[jarek m]

I'd say this thread automatically qualifies jarek m far beyond the misnomer, "Hummer Novice."


Thanks VegasGuy.:beerchug:

[jarek m]

Just made this a family activity. Putting wife to work.

http://i32.photobucket.com/albums/d45/Basia678/H2/002-1.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/003-1.jpg

[jarek m]

Parts washer was the best money I ever spend.
http://i32.photobucket.com/albums/d45/Basia678/H2/004-1.jpg


Little sand blasting and ready for paint
http://i32.photobucket.com/albums/d45/Basia678/H2/007-1.jpg

That cleaned up nicely.
http://i32.photobucket.com/albums/d45/Basia678/H2/006-1.jpg

[DRTYFN]

I'm at 123K and just replaced original air bags on the rear suspension. Water pump is just starting to weep a little bit. I need to start putting together a to-do list.

[jarek m]

Cracking the T Case.

http://i32.photobucket.com/albums/d45/Basia678/H2/005-1.jpg

:eek:
http://i32.photobucket.com/albums/d45/Basia678/H2/008.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/009.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/010-1.jpg

[jarek m]

I'm at 123K and just replaced original air bags on the rear suspension. Water pump is just starting to weep a little bit. I need to start putting together a to-do list.


Our rear air was a $1K three visits at the dealer NIGHTMARE!!!!! But I'm glad we kept it.

[Hellz]

:eek:
http://i32.photobucket.com/albums/d45/Basia678/H2/008.jpg

now, im no professional mechanic, but i think the spring thingy was the cause of your problems... everything else looks good!

[Hellz]

this is some impressive DIY work. i wish i had the balls to do this. i would say knowledge too, but i think you would throw the hanes book at me like what was posted earlier.....

im just scared with all the little parts, because i normally end up with "Spare parts" after i work on things that arent suppose to have spare parts..

[jarek m]

I thought that the fork was supposed to melt before the race comes apart?:notallthere:

[jarek m]

this is some impressive DIY work. i wish i had the balls to do this. i would say knowledge too, but i think you would throw the hanes book at me like what was posted earlier.....

im just scared with all the little parts, because i normally end up with "Spare parts" after i work on things that arent suppose to have spare parts..


Holly s**t me to, I thought it was only me.LOL!

[jarek m]

All washed, need parts and ready for reassembly.
http://i32.photobucket.com/albums/d45/Basia678/H2/011-1.jpg

[jarek m]

Farther down the rabbit hole.

http://i32.photobucket.com/albums/d45/Basia678/H2/012-2.jpg

More moisture.
http://i32.photobucket.com/albums/d45/Basia678/H2/014-1.jpg

WTF is that?
http://i32.photobucket.com/albums/d45/Basia678/H2/015.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/017.jpg

That diff is massive almost twice as big as a Rover diff!
http://i32.photobucket.com/albums/d45/Basia678/H2/018.jpg

This bushing is ok?
http://i32.photobucket.com/albums/d45/Basia678/H2/020.jpg

[Easy Ed]

:fdance: :fdance: :fdance: :giggling: :giggling: :giggling: Lucky Dog you ;)

I'm at 123K and just replaced original air bags on the rear suspension.

[jarek m]

I still got to take more stuff apart, but today I made a step forward

-Trace horn problem. DONE!


Tracing the problem up the wire harness.
http://i32.photobucket.com/albums/d45/Basia678/H2/003-3.jpg


http://i32.photobucket.com/albums/d45/Basia678/H2/007-2.jpg


I changed this piece before.
http://i32.photobucket.com/albums/d45/Basia678/H2/006-2.jpg


Spindle.
http://i32.photobucket.com/albums/d45/Basia678/H2/004-3.jpg



I changed it for a new one, just forget to take ALL of the old one out!
http://i32.photobucket.com/albums/d45/Basia678/H2/005-3.jpg


Rust everywhere. WTF.
http://i32.photobucket.com/albums/d45/Basia678/H2/008-1.jpg

[jarek m]

Diff ready to go back in.:excited:

http://i32.photobucket.com/albums/d45/Basia678/H2/019.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/020-1.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/021.jpg

[jarek m]

Front diff got installed today. Piece of advice to any one doing this, power wash the undercarriage before reassembly!!!
Holly crap how can a truck be so rusted with that amount of grease underneath it.

http://i32.photobucket.com/albums/d45/Basia678/H2/002-2.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/004-4.jpg

Well deserved!
http://i32.photobucket.com/albums/d45/Basia678/H2/007-3.jpg

[Faustus100]

A great job!!Keep those pictures coming!!:perfect10s:

[HumminNBoatin']

Putting that front diff back in single handedly is a real chore! lol. I had to do it by myself on my back in my driveway when I put my locker in.

[jarek m]

Putting that front diff back in single handedly is a real chore! lol. I had to do it by myself on my back in my driveway when I put my locker in.


:iagree:

[jarek m]

Got the TC parts this week, thanks to Brodie at http://www.ridgedemon.com/ :beerchug:
My chain looks same as new one, no more play or wear then the old one. But I'll still change it, we all know it would break the second I would put it back together otherwise.
http://i32.photobucket.com/albums/d45/Basia678/H2/008-2.jpg

My new (to me) mirror got here this week to.
This one besides the obvious damage, the fold motor is bad.
http://i32.photobucket.com/albums/d45/Basia678/H2/006-3.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/007-4.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/005-4.jpg

All done can't test it, the battery is dead
http://i32.photobucket.com/albums/d45/Basia678/H2/009-1.jpg




Tomorrow is the big day slapping the TC back together! I sure could use a manual for it :winkie:, anyone...anyone...

[jarek m]

$1.5k in parts this week, it all had to go in today.

Don't even ask me why...
http://i32.photobucket.com/albums/d45/Basia678/H2/003-5.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/004-6.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/014-3.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/015-2.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/017-2.jpg

Ooo, you want your car back then I suggest you get to work!
http://i32.photobucket.com/albums/d45/Basia678/H2/016-1.jpg

Everything that comes of got to get paint.
http://i32.photobucket.com/albums/d45/Basia678/H2/018-1.jpg


Tomorrow TC goes back in and Drive shafts.
http://i32.photobucket.com/albums/d45/Basia678/H2/001-2.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/002-3.jpg

[jarek m]

http://i32.photobucket.com/albums/d45/Basia678/H2/003-4.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/004-5.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/005-5.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/014-2.jpg

[Scarsman]

Very nice. I have already decided that when my Hummer is old and tired it is going to be rebuilt/restored and kept going. Why spend the money on a new rig, when nothing else will compare. Spend it on the one that's paid for and make it the way you want it.

[jarek m]

After working on it, I must say that this truck looks like it was build as a 3500 truck. If it wasn't for the plastic interior it's pretty solid truck.

[jarek m]

TC is in !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!:beerchug:

http://i32.photobucket.com/albums/d45/Basia678/H2/012-5.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/013-2.jpg

It wasn't that bad
http://i32.photobucket.com/albums/d45/Basia678/H2/th_014-4.jpg (http://s32.photobucket.com/albums/d45/Basia678/H2/?action=view&current=014-4.mp4)

[jarek m]

Got the drive shafts.

http://i32.photobucket.com/albums/d45/Basia678/H2/002-4.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/003-6.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/004-7.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/005-6.jpg

Trying to repaint the trim.
http://i32.photobucket.com/albums/d45/Basia678/H2/001-3.jpg

[jarek m]

Unfortunately the A/C does not work it also doesn't want to switch between outside and inside air, the controller goes a little crazy when I select that. Don't the unit got to be programed by the dealer? I think I read that somewhere.

[jarek m]

Test drive didn't go that good.

http://i32.photobucket.com/albums/d45/Basia678/H2/010-3.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/012-4.jpg

[Scarsman]

Leaking cooler? Did you have it apart, or is it a new problem?

[BLUETHUNDER]

I love threads like this. Keep the pics coming. Regarding some of those surface rust issues. Do you live in a very humid part of the states??.Ive never seen surface rust like that on interior componants.

[guruerror]

Dude...I'm all about DIY, but, man you are out of control. This is an awesome thread. You're the MAN! :clapping:

[jarek m]

All and all, every thing works just fine if not better. The PS cooler leek is a new thing but a easy fix, got a new cooler with lines on eBay for $40:D . The truck also is pulling a P0135 even thou all O2 sensors are new-ish, I'll give it couple of days maybe it clears it self. I still have to do the injectors only 7 came in still waiting for one.

On to the interior!!!!:soapbox:

[jarek m]

I love threads like this. Keep the pics coming. Regarding some of those surface rust issues. Do you live in a very humid part of the states??.Ive never seen surface rust like that on interior componants.

I think NJ is the most humid of them all and we just moved away from the coast line.

[jarek m]

My wife decided to change the color a bit. Nickel tone dose make it look a little less industrial and more elegant

http://i32.photobucket.com/albums/d45/Basia678/H2/005-7.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/006-5.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/002-5.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/001-3.jpg

Can't take the door apart without damage.:(
http://i32.photobucket.com/albums/d45/Basia678/H2/008-4.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/001-4.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/003-7.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/007-6.jpg

[guruerror]

Can you post a pic of what the back of one of the door panels looks like. I'm getting ready to pull mine off to have 'em Line-Xed and I was wondering how the 'leather' sections (top and arm rest) were attached to the plastic...easily removable? Not removable?

Thanks in advance!

[jarek m]

Can you post a pic of what the back of one of the door panels looks like. I'm getting ready to pull mine off to have 'em Line-Xed and I was wondering how the 'leather' sections (top and arm rest) were attached to the plastic...easily removable? Not removable?

Thanks in advance!

No, there "heat riveted" together that's why I'm keeping them in one piece for paint.

http://i32.photobucket.com/albums/d45/Basia678/H2/009-3.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/010-4.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/011-3.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/012-6.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/013-1.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/014-5.jpg

[guruerror]

No, there "heat riveted" together that's why I'm keeping them in one piece for paint.

Thanks for the quick reply...I think I may pop a back one off and try to work with those welds. I really want the panels to be Line-Xed. If I can get the leather bits, speaker grill, and the handle off I'm good...I'll have the remainder sprayed as is.

I feel confident that I can release those welds without permanently damaging the panel...just need to soften them up with a soldering iron. I'm gonna practice on the welds for the door panel pocket. My goal is to permanently remove the pockets from the rear doors anyway.

I may start on this project this weekend...I'll open a new thread once I do so I don't keep interrupting this one.

Thanks again...and GREAT work.

[Scarsman]

Thanks for the quick reply...I think I may pop a back one off and try to work with those welds. I really want the panels to be Line-Xed. If I can get the leather bits, speaker grill, and the handle off I'm good...I'll have the remainder sprayed as is.

I feel confident that I can release those welds without permanently damaging the panel...just need to soften them up with a soldering iron. I'm gonna practice on the welds for the door panel pocket. My goal is to permanently remove the pockets from the rear doors anyway.

I may start on this project this weekend...I'll open a new thread once I do so I don't keep interrupting this one.

Thanks again...and GREAT work.

I wonder if you could dremel out the welds without going through to the otside, and then reattach the panels with something like velcro strips, since they look like they have lots of overlap.

Or, what about using allen head bolts that match the ones for the dash? That might look sort of cool. The bolts would be in the plastic part, and with the LineX you probably wouldn't need washers on the outside. If you did you could use black ones.

[guruerror]

I wonder if you could dremel out the welds without going through to the otside, and then reattach the panels with something like velcro strips, since they look like they have lots of overlap.

Or, what about using allen head bolts that match the ones for the dash? That might look sort of cool. The bolts would be in the plastic part, and with the LineX you probably wouldn't need washers on the outside. If you did you could use black ones.

MOVED THIS TO A NEW THREAD: Door Panel Disassembly (2003-2007) (http://www.elcovaforums.com/forums/showthread.php?t=40144)

[BLUETHUNDER]

Thanks for the quick reply...I think I may pop a back one off and try to work with those welds. I really want the panels to be Line-Xed. If I can get the leather bits, speaker grill, and the handle off I'm good...I'll have the remainder sprayed as is.

I feel confident that I can release those welds without permanently damaging the panel...just need to soften them up with a soldering iron. I'm gonna practice on the welds for the door panel pocket. My goal is to permanently remove the pockets from the rear doors anyway.

I may start on this project this weekend...I'll open a new thread once I do so I don't keep interrupting this one.

Thanks again...and GREAT work.What colour are your rear pockets??. Mine are missing.

[BLUETHUNDER]

No, there "heat riveted" together that's why I'm keeping them in one piece for paint.

http://i32.photobucket.com/albums/d45/Basia678/H2/009-3.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/010-4.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/011-3.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/012-6.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/013-1.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/014-5.jpgYou have done a nice paint job on those interior parts....:clapping:

[guruerror]

What colour are your rear pockets??. Mine are missing.

I MOVE THIS TOPIC SO WE DON'T HIJACK THIS THREAD: http://www.elcovaforums.com/forums/showthread.php?t=40144

[jarek m]

Steering wheel buttons replacement.

http://i32.photobucket.com/albums/d45/Basia678/H2/005-8.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/006-6.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/007-7.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/008-5.jpg

:beerchug:
http://i32.photobucket.com/albums/d45/Basia678/H2/010-5.jpg

[jarek m]

Its like Christmas time today, more parts...

http://i32.photobucket.com/albums/d45/Basia678/H2/012-7.jpg

[Scarsman]

Very nice! The steering wheel buttons look easy enough to change. Good to know.

[guruerror]

Steering wheel buttons replacement.

Your the man if you were able to replace those without disassembling the new switches. I've replaced all four buttons...I had to take apart each one in order to get them installed. I just didn't have enough slack in the cable to install as your illustrations demonstrate.

Keeping all the lights working in this truck is definitely a challenge.

[lx4life]

Its like Christmas time today, more parts...

http://i32.photobucket.com/albums/d45/Basia678/H2/012-7.jpg

Hey Jarek I sent you a message about removing your front diff.

[H2Much]

You are the man! If I lived somewhere near you, I would pay you to do the same things for me and be my Hummer mechanic. I can't seem to find anyone anywhere who knows what they are doing when it comes to Hummers. Sad but true.

[jarek m]

Hey Jarek I sent you a message about removing your front diff.

Can't find it do it here JarekMaras@gmail.com

[jarek m]

You are the man! If I lived somewhere near you, I would pay you to do the same things for me and be my Hummer mechanic. I can't seem to find anyone anywhere who knows what they are doing when it comes to Hummers. Sad but true.


LOL! I'm not a mechanic. I'm in construction and I got a fleet of 5 vehicles and 2 trailers, if I wouldn't do the work myself I'll be working just to keep the trucks on the road! "Necessity is the mother of all invention" :o

[jarek m]

One of the last parts of the schedule overhaul, injectors!
http://i32.photobucket.com/albums/d45/Basia678/H2/003-8.jpg

The worst tool that I've ever owned!
http://i32.photobucket.com/albums/d45/Basia678/H2/004-9.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/008-6.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/010-6.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/012-8.jpg

I ended up doing it with a bent screwdriver.
http://i32.photobucket.com/albums/d45/Basia678/H2/013-3.jpg

Do not split that rail!!!
http://i32.photobucket.com/albums/d45/Basia678/H2/014-6.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/016-2.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/017-3.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/019-1.jpg

[jarek m]

My wife wanted to get on on that last bit. And what a satisfying job, wow now the truck MOVES!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!:clapping:

http://i32.photobucket.com/albums/d45/Basia678/H2/020-2.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/022.jpg


More of the snow ball effect, alternator is on it's way out, the lights dim every now and then. On the other hand the A/C fixed/programed it self!:)

[jarek m]

BIG thanks to the guy that came up with that, very useful!

http://i32.photobucket.com/albums/d45/Basia678/H2/001-5.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/002-6.jpg

[PHATBOYPIMP]

Obviously not including labor.....what is the cost of this overhaul going to be a the end? I am very impressed with your thoroughness and detail.

[jarek m]

Les then $2K:)

[PHATBOYPIMP]

Amazing :beerchug: :dancingbanana:

[jarek m]

Well that was short lived, got back from dinner today and the rear air suspension is out! I just got done with that pile of **** not to long back, everything is NEW on it. MBMIA!!!

[jarek m]

Today i got to do pads and rotors on H2, Green stuff pads and GSG cut rotors.
http://i32.photobucket.com/albums/d45/Basia678/H2/004-10.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/005-9.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/006-7.jpg

[slippy]

your some sort of hummer god. amazing.

[jarek m]

your some sort of hummer god. amazing.

Hahhahahah!!!! thanks.

[Cazador]

This has been amazing to watch. Thanks for the great pics and updates!!:beerchug:

[jarek m]

More fun today. For the past week or two wife been reporting strange behavior in the cockpit of our H2, random codes and warning lights coming on and off. Air compressor running all the time and the battery been going dead for past two days. Now we changed the battery about four months back so I doubt that's that. Also the headlights would dim from time to time going down the road at night and speedometer stopped working .
New alternator time.

http://i32.photobucket.com/albums/d45/Basia678/H2/003-9.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/002-8.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/001-6.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/002-7.jpg

[jarek m]

Already time for an update, remember these?
http://i32.photobucket.com/albums/d45/Basia678/H2/003-5.jpg

That's what the AUP one looks like today!!!!!!!!

http://i32.photobucket.com/albums/d45/Basia678/H2/IMG_7302.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/IMG_7303.jpg

http://i32.photobucket.com/albums/d45/Basia678/H2/IMG_7301.jpg

The other side is OK no sign of aging.

[H2 Bill]

What brand is the other one?

[jarek m]

What brand is the other one?


CARDONE SELECT Part # 661325

[H2 Bill]

CARDONE SELECT Part # 661325

Thanks!

[jarek m]

I got a new problem to play with, the truck won't start. It actually stalled in the entrance of the gas station, but filing up didn't make a difference.

Things that were happening over couple of weeks before.
Speedometer showing random speeds
Service air massage coming on and off at will
New installed in Sept battery dead three times

Here is what it looks like now (notice there are no icons ligating up but the check engine light, no codes though) :
http://www.youtube.com/user/Jarek13?feature=mhum#p/u/0/8gKrWzqIKxE


Things I've done recently that could be related:
Battery new (Got another one)
Alternator new
Ignition switch (three years old)

[jarek m]

Fixed it today, it was a bad starter. This were some weird symptoms...

http://i32.photobucket.com/albums/d45/Basia678/photo-1.jpg

http://i32.photobucket.com/albums/d45/Basia678/gDnZT.jpg

[leekyraj2]

so is this whole overhaul finally done? is the truck running good now?

[jarek m]

so is this whole overhaul finally done? is the truck running good now?


Hahahahaha!!!!
Instrument cluster is completely out and throttle position sensor is almost out.

[cashville]

bringing up this great thread!

[finbox]

I would say your a Hummer GOD...but I see you have a Land Rover..so you have alot of experience on rebuilding trucks!

I restored a 1967 88" Land Rover and learned alot from it.

[2010_5thgen]

wow...what a great rebuild thread. its a great feeling when you fix old worn out parts. the creidit card bill hurts, but its a great feeling when old rusted worn down parts get tossed out. hopefully i wont have to do this to my hummer for a while, but im in the stages of doing some of these upgrades to my silverado 2500 with 264K on it.

[jarek m]

I would say your a Hummer GOD...but I see you have a Land Rover..so you have alot of experience on rebuilding trucks!

I restored a 1967 88" Land Rover and learned alot from it.


72 88" i just finished for my wife, galv frame and all.

http://tabid.smugmug.com/photos/i-dTgwQt7/1/L/i-dTgwQt7-L.jpg

[jarek m]

wow...what a great rebuild thread. its a great feeling when you fix old worn out parts. the creidit card bill hurts, but its a great feeling when old rusted worn down parts get tossed out. hopefully i wont have to do this to my hummer for a while, but im in the stages of doing some of these upgrades to my silverado 2500 with 264K on it.


2k hurt lot less them 6.

[jarek m]

220k update.
All the restored parts are doing fine minus the boot on that one half shaft. $500 ebay compressor that we changed at 150~K is dead again but i think that was a good run.

New list.....
Rear door locks not working
Change instrument cluster
Extend rock slides
Drop steps
On star fuse
Day time running lights
Fix no start
Repaint the front end
Rear air fix

[jarek m]

Compressor is out debating between fixing the motor.... $150 or dual stage unit $1,000.

http://i32.photobucket.com/albums/d45/Basia678/E43D2AC1-E884-4FEE-915F-AE1655CE4D24-1795-000001943E5E02F5.jpg

[jarek m]

Rear door locks not working
Change instrument cluster
On star fuse
Day time running lights



Blown relay, door locks fixed.
http://i32.photobucket.com/albums/d45/Basia678/50429A8A-34B0-4CEB-98D3-EAFCC4F0F700-1676-000001ADD712FCF0.jpg

Also replaced the instrument cluster, looks same. Pulled the fuse for onstar and wired up the day time running lights.

[pdxrealtor]

And I felt good after a complete front end suspension rebuild. Good God......

Nice work

[jarek m]

And I felt good after a complete front end suspension rebuild.


That's quite a job, this forum has changed so much ever since I started lurking around years back. Used to be stereo and rims upgrades top to bottom, now it's a proper Tech section. Love it! :D

[jarek m]

ECM came in today, I'll install it after dinner, make my wife perform a half an hour long introductions, lol.

http://i32.photobucket.com/albums/d45/Basia678/6ae3140d48809b982a6c8b82f47ab577.jpg

[jarek m]

http://i32.photobucket.com/albums/d45/Basia678/DE920901-1786-402C-A8C9-0391541448CB-368-000000504EA892D4.jpg

[jarek m]

Sandblasted the bumper today and attacked the rust on the crossmember.

http://i32.photobucket.com/albums/d45/Basia678/3FD3F9A7-CC57-4240-AFCB-30A6E71EC447-284-00000015DBDEF650.jpg

http://i32.photobucket.com/albums/d45/Basia678/5841FB59-FF5D-4498-AA22-BC5103B0CA91-284-00000015DEFC2324.jpg

[jarek m]

New paint.

http://i32.photobucket.com/albums/d45/Basia678/8BE1C24D-F2B5-45FD-B251-EC5888E66665-284-0000001C096CB7AA.jpg

[PaHumBug]

http://i32.photobucket.com/albums/d45/Basia678/DE920901-1786-402C-A8C9-0391541448CB-368-000000504EA892D4.jpg
How are you removing the chrome on that grill? How big of a pain is it?

[Hellz]

i removed all the chrome off of mine with a power washer.

total time i think maybe an hour. from there i went and had it LineX

not sure what he did for his

[iwillnc]

Is that por15 your putting on the rusted crossmember? Brush on by the looks as well?

I need to get something and start getting the rusted knicks on my frame where something wiped the wax off the frame

[jarek m]

i removed all the chrome off of mine with a power washer.

total time i think maybe an hour. from there i went and had it LineX

not sure what he did for his


I heard about the power washer trick but the temp. in NJ is to low for that, so I'm doing in the HARD way scalpel and cutters.

[jarek m]

Is that por15 your putting on the rusted crossmember? Brush on by the looks as well?

I need to get something and start getting the rusted knicks on my frame where something wiped the wax off the frame


No, I'm using oldtimer recipe for "wax-oil". This frame is going to end up galvanized at some point anyway...

POR-15 is great I recommend it.

[iwillnc]

"No, I'm using oldtimer recipe for "wax-oil". This frame is going to end up galvanized at some point anyway..."

Do explain? Is the wax identical to the factory wax on the frame? did you get down to bare metal before you applied it? How is it made?

Also how much, not including time spent removing everything from the frame would it cost to have the frame galvanized? Would it be dipped in zinc... or.....


Curious minds wonder.

[jarek m]

Do explain? Is the wax identical to the factory wax on the frame? did you get down to bare metal before you applied it? How is it made?



No way, this recipe is before everything had to be environmentally friendly and safe for consumption in case your kids decide to lick the frame.

Power wash area.

Tar, axle grease, USED diesel engine oil.... Mix all, boil, put the fire out, apply hot. (Keep out of reach of children) :)

[jarek m]

Also how much, not including time spent removing everything from the frame would it cost to have the frame galvanized? Would it be dipped in zinc... or.....


Curious minds wonder.


My local guy...
Galvanizing
V&S Amboy Galvanizing LLC
1190 Amboy Avenue
Perth Amboy, NJ 08861 USA
Phone: (732) 442-7555
Fax: (732) 442-5560
http://www.hotdipgalvanizing.com



Just had a visit at V&S Jon in sales says no job is to small, walk-ins welcome.
They do architectural finish and acid dip. Got to clean the paint before.
If we get over 500lbs it works out to be about 50 cents per pound and the closer to 4000lbs we get the deeper the discount gets.

[iwillnc]

Tar, axle grease, USED diesel engine oil.... Mix all, boil, put the fire out, apply hot. (Keep out of reach of children)

Hmm.. I don't think that's something to cook on the stove... haha
But cool to know...


The galvanizing is so cheap, that's pretty cool.

[jarek m]

Moving along...

http://i32.photobucket.com/albums/d45/Basia678/3af3e865ec458c6eaa6f3e29514ab047.jpg

[jarek m]

Final front end colors, still got to repaint, the finish isn't good but that's what it's going to look like.

http://i32.photobucket.com/albums/d45/Basia678/282856E8-8BD1-4B6F-ADE1-EF00964AED50-1212-000000E626653DA8.jpg

[iwillnc]

Did you remove the letter out of the grille prior to painting? Are you going to put them back on?

[jarek m]

Did you remove the letter out of the grille prior to painting? Are you going to put them back on?



Yes, waiting for warmer temps.

[jarek m]

Who is ready for more fun!!!?

[iwillnc]

Waiting patiently everyday.

[DRTYFN]

Good thread. I enjoy watching someone capable fixing their own stuff. :beerchug:

[DRTYFN]

I got a new problem to play with, the truck won't start. It actually stalled in the entrance of the gas station, but filing up didn't make a difference.

Things that were happening over couple of weeks before.
Speedometer showing random speeds
Service air massage coming on and off at will
New installed in Sept battery dead three times

Here is what it looks like now (notice there are no icons ligating up but the check engine light, no codes though) :
http://www.youtube.com/user/Jarek13?feature=mhum#p/u/0/8gKrWzqIKxE


Things I've done recently that could be related:
Battery new (Got another one)
Alternator new
Ignition switch (three years old)


What happened to this video? I'm having issues with my instrument cluster, windows, air suspension button, seat heater buttons and a couple of other things and trying to find a common denominator. Ideas?