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2500LD --> HD Front Bumper Swap

6K views 4 replies 2 participants last post by  rockinjer 
#1 ·
Cliffs: I need a new front bumper and want to upgrade to a 2500HD with fog light holes. My truck is wired for fog lights. Help me put together a list of parts to do so.
1. HD bumper kit - chrome "upper" section (could be reused), fog light lower section, 2" filler panel between chrome and headlights/grille, brackets
http://www.ebay.com/itm/200847158192?_t ... EBIDX%3AIT
2. HD specific cab mounts (6), radiator mounts (2)
3. fog lights and brackets
http://www.ebay.com/itm/03-06-GMC-Sierr ... 5x&vxp=mtr
4. fog light switch for cabin
http://www.ebay.com/itm/BRAND-NEW-GENUI ... Jn&vxp=mtr
5. I'm sure there are some nuts/bolts for the fog lights I am missing, but can't find an exploded parts diagram for - possible BCM reflash to get fogs to work

For those with an attention span:

While installing the 4F/1.5R lift/level and 33x12.5 tires onto my 2003 2500 Base, I made a few observations:
1. I need side steps for my wife, and the body mounts appear shot (considering all 4 shocks did not re-expand when compressed, not surprised)
2. the front lower bumper (plastic) is torn/broken off the chrome upper at the corners (when I went to trim it found that)
3. the chrome upper is completely shot, the truck appears to have factory fog light harnesses behind the front bumper

I would like to "upgrade" to a 2500HD bumper after doing a lot of reading. Apparently, it uses the same chrome piece, but I can get a fog light hole lower. I do not care if it's painted or not, I plan to Herculiner it to match other pieces on the truck I did like that. According to my reading, a 2500HD is 2" higher in the front thanks to larger cab mounts to accommodate the bigger drivetrains (effectively, a factory 2" body lift). This 2" is made up for by a filler piece above the chrome upper bumper but below the factory grille/headlights. I actually like this piece versus doing a body lift and just mounting the factory bumper higher, I would also Herculiner it. Since my factory chrome is trash, I am going to Herculiner it to see, but I think the Herculiner filler/chrome upper/Herculiner lower would look good.

In order to accommodate that setup, I would need to lift the cabin by 2". I have seen Energy Suspension and Prothane kits installed here and other forums, and I do not like the comments about increasing road noise/NVH/ride stiffness (the wife is already annoyed enough at the noise from the meaty 33's but appreciates their superior snow capability and the increased stiffness of cranked aftermarket keys and Bilstein 5100s versus the stock completely blown shocks and probably worn out torsion bars). I am thinking I could accomplish a happy medium by ordering the 6 cabin rubbers, 2 radiator pucks, and the longer HD hardware (I am expecting mine to be a total loss due to rust even if long enough).

Am I correct so far in this line of thinking as far as part fitment/placement? I cannot find an exploded parts diagram for the front bumper, but that appears to be all the brackets to hold on the HD bumper are included in that kit except for #3, which I believe my stock truck has. I am sure all the bolts will just transfer over.


I realize this picture links to 2007 Sierra 1500 but on my phone I found a 2003 Sierra 2500HD and it's the same exact picture.

This will leave me with a bed requiring a 2" raise to match, but that sounds like a relatively easy and cheap project to tackle after the fact.
 
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#3 ·
Some notes I have found so far:

1. There seems to be some huge argument whether the 2500HD gets a "body lift" from the factory or if it is a frame rail difference. From my reading, a 2500LD like mine is essentially a 1500HD with the 8" C-channel up front tapering down to a 6" C channel in back. A 2500HD gets a 2" body lift in front and a 8" C-channel in back to accommodate the diesel/Allison or 8.1L combinations. Some argue that this is not an actual body lift, the 2500HD front frame is bigger. I haven't measured mine, and I do have a neighbor just down the street that has a NBS HD crew cab 8" bed (what I should have bought obviously...). I think it would be pertinent of me to measure mine and go make friends to measure his and for future questions. Additionally, if you look up the HVY RPO code, it specifically says HD 2" body lift. I do not have this code. Dorman lists separate part numbers for a 2003 2500 radiator mount and 2003 2500HD radiator mount, I cannot find cab mounts from them. Additionally, both the Prothane body mount kit and the Energy Suspension body mount kit are listed as only fitting HD. GM part numbers appear to be the same, but all are discontinued, so my only option for replacing the cab mounts in any situation is an aftermarket polyurethane kit.

2. The stock transfer case shift rod needs to have a 1/2 x 1" extension welded into it according to Performance Accessories 2" body lift kit. I am trying to find a site that lists different part numbers for a HD rod so I can just order one up (a stock one is $30.55 which to me is worth my time cutting the stock one and welding it - if there are any wear items on the rod, they are probably worn out anyway just like everything else on this truck).

3. No one makes a lift kid for a 2500LD. Performance Accessories was unhelpful in trying to figure out how to make a 2500HD work, but did send me the install instructions which have a parts list in it. I have the rear sorted out pretty well - I need two 2" tall x 2" wide lift blocks, four 2" tall x 3" wide lift blocks, six M12x1.75x160mm bolts, and a fuel filler extension 2" x 4" and clamps (all these are ordered and on their way). I do not have the spare tire in stock location so I don't need to fiddle with that, and I am leaving the rear bumper in the stock location for the time being (moving it up with the hitch in my mind compromises tow capability...I will find my own solution in the future, probably a fabricated bumper).

4. For the front I negate all the brackets and fan shroud mods with an electric fan. The minor details like brake lines and P/S lines I will deal with as I come across them. The only "custom" piece I need is the steering shaft extension (PA lists this as SE-4500 which I cannot find online and they are closed for the holiday to call them). I can either do that, but I think I would rather just install a HD steering shaft (according to Dorman, different part numbers - according to Autozone's site, 425-179 is for a non-HVY and is 15.125" long and 425-186 for HVY is 16.25 long). Unfortunately, the part is very rare online (discontinued). It may end up being cheaper just to order a solid steering shaft kit and fabricate my own, and tighten up the steering in the process. Again I am leaving the bumper in the stock location. I am hoping that HD front bumper kit I listed above with the 2" bumper spacer will fix any gap.

What I really need to figure out at this point is are the cab mounts on an HD an actual 2" raise - I need to order the polyurethane kit either way, so if they are, that saves me from having to buy front body raise mounts (8) and washers (8). I would still replace the stock bolts. Regardless of what I do, I think I'm going to come in significantly under the cost of a 3" lift (~$500 shipped) mostly by not needing their proprietary brackets. I think my best bet with everyone being closed for the holidays is go make friends with the HD and get some measurements/pics.
 
#5 ·
Have you finished this build yet? im curious to do the same thing to my 06 1500HD, seems there is not a lot of information about this subject of the 2" body lift on the 2500HDs.
I am curious are the 2500HD cab bushings just 2" taller than ours, or are the brackets sitting higher on the frame?
 
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