Tony-CA

Catalyst efficency is determind by pre and post O2 switch ratios. The post cat O2 shouldnt switch much if the cat is hot and working. Since you have a Snap on Modis you should graph all 4 O2 pids and watch the values. What is B2S2 doing? What is B1S1 doing when B1S2 is at 400mv? The 400mv youre seeing could be a pcm bias voltage from a internal open in the O2 itself or a open wire to the pcm. If testing determines the O2 is bad Id go with a OEM replacement.

Is it a 6.0L or 7.3L power stroke?

This is probably a long shot...does anyone know the part number for the steering gearbox pinion shaft needle bearing? The gearbox itself is a Delphi 680. GM does not not offer that bearing as a service part. They do offer the seals, snap ring, retainer ring, and o-rings though. I'd like to see if a place like Kaman Bearing may be able to get that bearing before I take it apart.

You may have loose terminal(s) in the OBD2 connector. Is the pin grip good?

2004+ trucks dont have external fuel filters. The filter comes with the pump assembly. With diagnosis, labor, parts markup to cover overhead and warranty problems if the pump fails, the price seems about right. Do you expect labor for free? Or parts at cost?

Im not sure how durable that pump is. Im mainly refering to aftermarket junk like the stuff you get at Autozone.

The tech 2 cannot turn torque management off. Actually, the tech 2 cannot modify any calibrations outside of tis 2 web downloads which are factory updates that comply with emission regulations.

I'd say 60k-80K is the average lifespan. Just make sure you replace it with a Delco part.

a flush machine isnt required. remove the upper trans cooler hose at the rad. stick a hose on both ends. put those hoses in a 5 gallon bucket. start the engine and add trans fluid until the fluid comes out clean.

Thats incorrect. Its more like 25 inch pounds of pinion drag(bearing pre-load). The only way to replace the crush sleeve and set up pre-load properly is to remove the pinion gear. By doing this you must remove the carrier. At this point you might as well replace all the bearings. It is possible to just replace the seal though. Mark the position of the pinion relative to the nut. Remove the nut and remove the yolk then replace the seal and reinstall the yolk. Tighten up the nut until or slightly after the marks line up. By doing this you wont disturb the set preload. This is assuming the pinion bearings are still ok. You should also check the diff vent for blockage.

You cant pull it out from the top. The door panel must come off and it will snap off from the bottom.

A bad turn signal/hazard flasher module can cause a left turn signal=hazard light problem. It's located behind the interior fuse block.

Since you cant feel the misfire and all cylinders misfire counters are counting up Id try a crankshaft variation relearn procedure first. Did you have this done after the custom PCM install? The P0446 relates to the vent portion of the evap system being blocked. You may have a plugged canister.

The transfer case and 4l65e both use dexron III. The tranfer case input shaft has a seal. The rear of the transmission that bolts to the transfer case uses a gasket to keep fluid from leaking externally.

you didnt flush the transmission fluid. all you did was a filter and gasket replacement.

It's time to take it to another shop. Most dealers are like the one you describe in that they specialize in swaptronics. It's all about about guessing not checking to them.

AWD SS trucks dont have driveshaft carrier bearings. Its just a one piece driveshaft straight to the transfer case.

Nevermind, I just realized you have an 05. New vehicles are smog exempt for 6 years during CA registration renewal.

Dou live in Nevada or California? What I mentioned earlier only applies to the CA smog check program.

You can get away with having two non-continuous monitors not run to completion. The non-continuous monitors the bar 97 looks at, as far as our trucks are concerned, are Catalyst, Evap, O2S htr., and O2S performance. These are called non-continuous monitors because it takes certain parameters(drive cycles) for these monitors to run to completion unlike the misfire monitor, for example, which is continuous. 200 miles is a bit much but it would most likely gaurantee a successful Pass for the OBD2 functional check.

Thanks.

Does anyone know with certainty if the hood and grill will fit for a 06 conversion?

I'm willing to bet someting is leaking above the pan like a trans. cooler hose fitting. Does it leak more with the engine running?

I've tried pretty much everything with the 8 degree shim being the best solution. I think other guys on here with the hanger-shackle combo ALL have some kind of vibration..some more severe then others. Of course it's all relative to how we individually precieve it. Some may say they don't have a vibration where in fact they do. Their threshhold is just a bit different.

redrock4x4.com. Part number RE1469. 3/8 center pin bolts are included. I had to drill out the holes though...the shims came with 5/16 holes.