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2004 Impala rebuild thread

 
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Jeff
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PostPosted: Thu Aug 18, 2016 11:52 pm    Post subject:  2004 Impala rebuild thread Reply with quote

It's been a very long time since I've posted here. Where to begin...about a year and half ago I was given back, free of charge, the 2004 Impala I bought brand new at Cavenaugh Auto World in Walnut Ridge, Arkansas. They just wanted it out of their yard. It had either 2 or 3 miles on it at time of purchase and I really enjoyed the car the entire time I had it. It was the first brand new car I bought myself. I kept the car until sometime in 2010 and roughly 68K miles. The time after I sold it wasn't kind to it....It had been knocked on both front corners and been rear ended by a lincoln towncar, but just. All were relatively light hits and did minimal damage(all cosmetic). The big issue with the car was that the person I sold it to let the LIM gaskets fail, continue to just pour in coolant, and drive it until the head gasket failed. There was no intermix upon inspection as the oil was clean and it still ran well, but ran hot. I towed the car home and then procrastinated for about 11 months. Earlier this year I began by tearing down the engine and found number one cylinder head gasket to be toast. The spark plug for that cylinder had also partially melted. I gathered all the necessary parts to repair. I used the Dorman LIM reseal kit with the upgraded metal gaskets and used FelPro severe duty head gaskets. Did a complete tune up and service while I was at it, new brakes and rotors all the way around, and new Hankook tires mounted on upgraded LS wheels. The car now runs great. I drove it for about 4 weeks straight every day.. It turns out to still be a really great car mechanically despite its neglect. It actually drives much nicer than my 09 Sable Premier. After I was confident that the fix had held on the engine I tore into the body issues. I will be posting a series of pictures that document this cars journey from this point.
Before:
http://i464.photobucket.com/al.....ushrsj.jpg
This one looks okay, but had a big dent that left some ripples when pushed out
http://i464.photobucket.com/al.....yuqfbl.jpg
New mirror because old one was missing:
http://i464.photobucket.com/al.....iczkba.jpg
Interior:
http://i464.photobucket.com/al.....vj9suv.jpg
Bumper cover damage:
http://i464.photobucket.com/al.....t8hyp7.jpg

Torn apart:
http://i464.photobucket.com/al.....ir9ood.jpg
http://i464.photobucket.com/al.....d1dzso.jpg
http://i464.photobucket.com/al.....obiq7z.jpg
http://i464.photobucket.com/al.....fcpaub.jpg
http://i464.photobucket.com/al.....rww0or.jpg
http://i464.photobucket.com/al.....eolqi9.jpg

Initial fit:
http://i464.photobucket.com/al.....zs7mko.jpg
http://i464.photobucket.com/al.....etkmtz.jpg
Rear bumper removed:
http://i464.photobucket.com/al.....u8ssat.jpg
Other than foam damage there's no further damage:
http://i464.photobucket.com/al.....tljibz.jpg
http://i464.photobucket.com/al.....7ict30.jpg
Fresh new assemblies TYC NSF Certified:
http://i464.photobucket.com/al.....clmrbj.jpg
http://i464.photobucket.com/al.....dsoxso.jpg
Took entire dash apart and deep cleaned:
http://i464.photobucket.com/al.....l80bgi.jpg
http://i464.photobucket.com/al.....jcw580.jpg
http://i464.photobucket.com/al.....otp5un.jpg
Interior removed and power washed carpets going back in:
http://i464.photobucket.com/al.....kpq4wo.jpg
Some stains remained, but those are hidden under the seat:
http://i464.photobucket.com/al.....gnhup8.jpg
Color was coming off of door panel so I re did those and gave them the "upgraded" LS look by color matching the top color just under the woodgrain(this would be cloth on some)
http://i464.photobucket.com/al.....ozpgvc.jpg
Rear bumper on:
http://i464.photobucket.com/al.....w51nws.jpg
http://i464.photobucket.com/al.....yvbzbk.jpg
Found these at a PullApart...$ 50.00
http://i464.photobucket.com/al.....s2ckcv.jpg
http://i464.photobucket.com/al.....qt5eks.jpg
http://i464.photobucket.com/al.....gmwqy.jpeg
http://i464.photobucket.com/al.....th9en.jpeg
http://i464.photobucket.com/al.....wktkks.jpg
http://i464.photobucket.com/al.....7siewy.jpg
http://i464.photobucket.com/al.....ljlrvs.jpg
http://i464.photobucket.com/al.....wfxm4h.jpg
http://i464.photobucket.com/al.....xy3pt3.jpg
http://i464.photobucket.com/al.....nghk8z.jpg
http://i464.photobucket.com/al.....pq77d3.jpg
http://i464.photobucket.com/al.....hshrpl.jpg

All that's really left is to paint the passenger mirror and install that and to paint the drip rail moldings that I removed from the roof due to heavy oxidation and seperation and then reinstall those. Beyond that, I will service the transmission and install a trans-go kit, and to install new suspension at all four corners. The car currently turned 140K miles the other day when I took it out for a couple hours on the highway.
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Chamber
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Joined: Oct 02, 2010
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Location: central NJ

2004 Chevrolet Impala


PostPosted: Fri Aug 19, 2016 6:44 pm    Post subject:   Reply with quote

You do very nice work!
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pdb
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Location: Winston-Salem, NC

2004 Chevrolet Impala


PostPosted: Fri Aug 19, 2016 8:47 pm    Post subject:   Reply with quote

Those TYC headlights look pretty good. Did they fit ok? Mine are starting to look pretty cloudy.
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Jeff
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Posts: 259
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PostPosted: Fri Aug 19, 2016 9:37 pm    Post subject:   Reply with quote

They fit just as nice as the OEM ones that I took out. They don't look cheaply made either. TYC has a value line and an NSF certified line. These are the NSF certified quality ones(supposed to be OEM quality) which I picked up for the same price as the cheaper ones. I think I gave about $55 each for them. I've used TYC on other cars before and never really had any issues with them.
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