My 87 R10 still has the cat but no muffler. Greater Atlanta requires emission testing back 25 years, part of which is visual inspection. 2012 was the last year my truck needed test
I believe you will find zero fluid, and severe mechanical carnage! Pretty sure 75 degree pinion travel is more than spider gears. By the way, I would be very reluctant to plow with a 700R4 transmission.
You might want to pull an axle shaft and count splines. Maybe you can use the 5 lug axles in your new differential. I bet you can also swap backing plates and all your brake parts too
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Your installation may be done correctly, but like Big Chip mentioned, may have a crack in the manifold. Use a mirror and a really good light and inspect the lower side of the manifold. I found a crack on my truck when removing the transmission, wasn't even noisy yet! Good luck
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Perhaps someone can correct me, but I don't believe that the squares had a "mechanical" oil pressure gauge. Thought it was either electrical gauge or an oil warning light that is also electric.
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I bet it was ordered, I never see manual shift t-case at work unless it's a base model WT. You sure it's really a Z71?
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I'm using Tapatalk right now so I can't see the picture you referred. I still think that weight is huge! Perhaps search for an image of a GM flex plate for the L31?
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Just got thru reading your post. Isn't the L31 a small block? The photo in post #69 shows a flex plate with a huge weight as seen on external balance 400 or 454 engines. Just a thought
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When you find the root cause of failure to be the ignition module, I would recommend that you buy only ac Delco for quality assurance. Heck, buy 2 and keep the spare in the glove box! Simple fix
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I don't think an overfill condition in a gear driven t-case would cause noise, probably only leaks. It's "splash" lubricated like the differential, no pump to cavitate or surge.
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Might have transmission fluid leaking into transfer case causing the over fill condition. Check transmission fluid level too
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That 03 fuel tank mounts inside the frame rail. The square body tank mounts outside. I'd buy and 87 tank and sending unit, install your pump and go! New tanks and sending units are relatively inexpensive