Hall Brothers Automotive: Frame Replacement

Parts Inventory:

GMC Frame

POR-15

Krylon Rubberized Undercoating

Dorman Torsion Bar Mounts

Dorman Shackles

AC Delco Fuel Line, Pressure Return and Vapor Line Assembly

AC Delco Fuel Pump

AC Delco Charcoal Canister

AC Delco Rear Shocks

AC Delco Idler Arm

AC Delco Pitman Arm

AC Delco Upper Control Arms

AC Delco Brake Line Kit

AC Delco Lower Ball Joints

Moog Lower Shock Mount Bushings

AC Delco Sway Bar Links

Moog Inner Tie Rods

Centric Pads and Power Stop coated rotors

AC Delco Calipers
Energy Suspension Polyurethane Radiator Support and Cab Mount Bushings

We were not a big fan of the Krylon Rubberized Undercoating it didn’t adhere well to the frame. This may be due to the POR-15 coating we used prior in their defense.

This is a 2000 GMC Sierra 1500 that we purchased used and are replacing the frame on. Once finished the plan is to keep it for personal use. We will continue posting updates as we work on it.

The existing frame is heavily rusted and the shock crossmember had actually broken off the frame.

Shock crossmember broken off frame.

We removed the hood, front fenders and radiator support to inspect for rust and lifted the cab off the frame. The radiator support and body mount bushings were totally worn out and need to be replaced also.

Cab lifted off frame.

We purchased a used frame with minimal surface rust. After power washing we painted with POR-15 to seal and prevent rust.

Frame painted with POR-15

Applied rubberized undercoating to complete the frame. We also cleaned the rust off the transmission crossmember and torsion bar crossmember and spray painted. New torsion Bar Mounts were needed.

Completed frame with rubberized crossmember.

Updated: July 5, 2018

We've removed the engine, transmission and transfer case from the old frame.

Engine and Transmission

Cleaned and painted the leaf springs and installed new rear shackles and differential on the new frame. The differential still needs to be cleaned and painted when time permits.

The exhaust was also transferred over. This was left as is since it was in good shape.

Shackles on right rear

The old fuel lines had rotted out so all new lines are bolted on. Below you can see the new Fuel Line, Pressure Return and Vapor Line Assembly.

We power-washed the front differential and installed it onto the frame.

The existing fuel tank was cleaned and installed along with a new fuel pump assembly. The charcoal canister, a part of the emissions system, was also replaced. The fuel pump failure caused the original canister to become saturated.

New rear shocks were added. You can see the right rear shock in the picture below.

Updated: July 9, 2018

Installation of new front end components (idler arm, pitman arm)

New upper control arms.

Driver

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Passenger

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New Brake Lines. The old lines had a lot of rust so we replaced just to be safe.

Cleaned and painted torsion bars, lower control arms and torsion bar keys.

Torsion Bar

Lower Control Arm

Torsion Bar Keys

Lower control arms with new ball joints and lower shock mount bushing on both sides, front shocks, front sway bar and links, inner tie rods front brakes installed with new hoses.

Engine, transmission and transfer case are installed on new frame.
New calipers on the brakes are also shown here.

Frame and radiator support mounting holes original size.

This is a Canadian built truck which was only manufactured for 2 years between 1999 and 2000 and we were not able to find the correct bushings for this frame.

The original frame holes were 40.8 millimeters.

The holes had to be altered to accept the 52 millimeter bushings that were available for this style of truck.