Author Topic: Rear Tailpan Replacement  (Read 15006 times)

Offline 89Suburban

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Rear Tailpan Replacement
« on: October 03, 2011, 11:25:16 am »
Anybody ever see a write up on this? I need to do mine.  :-\

1989 GMC Suburban V-1500/5.7 L TBI/700r4/NP241C/GM 10 Bolts

Offline slammed79

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Re: Rear Tailpan Replacement
« Reply #1 on: October 04, 2011, 05:22:42 pm »
For your Burb? I haven't seen a write up myself, but I'd imagine its gonna require a bunch of bracing, cutting and welding.

How about some pics of yours, is it all rusted out?
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Offline gharris79

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Re: Rear Tailpan Replacement
« Reply #2 on: November 30, 2011, 01:55:18 pm »
I replaced them on my last 2 Blazers. The way I figured would be best is to unbolt the body and get the back up in air about 6 inches off the frame. I didn't realize mine was that bad until I was lowering the tailgate and it practically fell off lol.
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Offline 89Suburban

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Re: Rear Tailpan Replacement
« Reply #3 on: January 15, 2012, 12:00:34 pm »
Thanks for the replies, I did mine, let me dig up the pics.

1989 GMC Suburban V-1500/5.7 L TBI/700r4/NP241C/GM 10 Bolts

Offline 89Suburban

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Re: Rear Tailpan Replacement
« Reply #4 on: January 15, 2012, 12:02:10 pm »
Here is some pics of the rotted out cross member on the truck:






















1989 GMC Suburban V-1500/5.7 L TBI/700r4/NP241C/GM 10 Bolts

Offline 89Suburban

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Re: Rear Tailpan Replacement
« Reply #5 on: January 15, 2012, 12:03:47 pm »
If you look close at the last 2 pics, you can see the floor sagging around the body mounts on the door sill there, it's like that on both the right and left sides, and the tail pan is actually sitting and rubbing on the bumper brackets as you can see the rust scrub marks in some of the pics on those bumper brackets.

I bet I will get another 1" of lift in the rear of the body after this is done, and it will remove some stress from the other body mounts and body frame parts in the rear of the truck.

Little by little I am going to start picking away at soaking fasteners and chasing threads that is holding this all together to prep for this project. I think I will be able to save the rubber parts on the rear mounts, just need to replace the bolts, nuts and washers.

Got to get the bumper in a ready to remove position also, as it has to come off to access this area. This will also give me a chance to attack any rear body and chassis area with my needle chisel gun to clean that shoot off and rust reform it.

1989 GMC Suburban V-1500/5.7 L TBI/700r4/NP241C/GM 10 Bolts

Offline 89Suburban

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Re: Rear Tailpan Replacement
« Reply #6 on: January 15, 2012, 12:06:14 pm »

1989 GMC Suburban V-1500/5.7 L TBI/700r4/NP241C/GM 10 Bolts

Offline 89Suburban

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Re: Rear Tailpan Replacement
« Reply #7 on: January 15, 2012, 12:07:36 pm »
I got the bumper off, had to cut 4 bolts, PB Blaster and a thread die didn't help in getting the nuts off. Got it temp mounted back on with 2 regular hex head bolts. My tag light took a crap too, must have been from all the vibration, and the lens screws are rusted, so I got to find a factory or aftermarket plate light before I get a ticket. I smashed a finger too.




















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1989 GMC Suburban V-1500/5.7 L TBI/700r4/NP241C/GM 10 Bolts

Offline 89Suburban

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Re: Rear Tailpan Replacement
« Reply #8 on: January 15, 2012, 12:08:53 pm »
Ugly stuff here....










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1989 GMC Suburban V-1500/5.7 L TBI/700r4/NP241C/GM 10 Bolts

Offline 89Suburban

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Re: Rear Tailpan Replacement
« Reply #9 on: January 15, 2012, 12:14:27 pm »
Last night after work I got the old body bolts cut out of the floor and installed the new ones. I will be trying to put this part in today. Wish me luck. 
























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1989 GMC Suburban V-1500/5.7 L TBI/700r4/NP241C/GM 10 Bolts

Offline 89Suburban

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Re: Rear Tailpan Replacement
« Reply #10 on: January 15, 2012, 12:15:13 pm »
Here is the RV plug installed in the bumper:


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1989 GMC Suburban V-1500/5.7 L TBI/700r4/NP241C/GM 10 Bolts

Offline 89Suburban

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Re: Rear Tailpan Replacement
« Reply #11 on: January 15, 2012, 12:17:10 pm »
This kicked my butt, but I am very happy with the results, truck is a lot more solid now. This product fit perfectly, had all necessary threaded holes, even had holes for the body wiring harness clips to pop into.

Took a lot of cutting and grinding, but I am over the hump, and can pic away at the small finish work as I please. I sprayed a lot of the Rustoleum Rust Reformer all over everywhere, even the back side of the bumper.

Took me about 4 or 5 hours of actual replacement work. Doing all the prep work before hand, like getting fasteners loosened and getting the body mount bolts replaced before hand made a huge difference.

You can see in the comparison pics of the old and new parts that 75 percent of the original support channel is completely missing.

Now I am on the boat drowning my aches and pains away, lol. Enjoy the pics.




















































































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1989 GMC Suburban V-1500/5.7 L TBI/700r4/NP241C/GM 10 Bolts

Offline 89Suburban

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Re: Rear Tailpan Replacement
« Reply #12 on: January 15, 2012, 12:21:03 pm »
As you can see I had to notch out the quarter panel to get the part to swing in without picking the body off the frame.

1989 GMC Suburban V-1500/5.7 L TBI/700r4/NP241C/GM 10 Bolts

Offline Captkaos

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Re: Rear Tailpan Replacement
« Reply #13 on: January 17, 2012, 05:27:05 pm »
This is an awesome post for the Tech section!