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I have a 2004 Z71 Hoe and my wife has a 2004 GMC Yukon. Both have close to 150k. Neither has had any issues other than reg maintenance. Very good vehicles.

RC keys with 1.5" rear spacers. 35x12.5x17 Cooper STT's. Minor cutting and no rub at all, even when wheeling.

I have the RC leveling kit on my 04. I didnt use the 3/4" spacers I replaced them with 1.5" spacers. With some trimming I'm running 35-12.5-17's cooper STT's. I love the look.

Just a leveling kit, you'll be able to fit 33's fine. You could go slightly bigger but your gonna need to trim some of the plastic inner liner. Mainly on the driver side by the windshield washer bottle. I've got 35-12.5-17's on my 04 Hoe but it required lots of trimming with a level kit and 1.5"...

I believe there is one by the gas tank and the other is close to the intake manifold on a 2002.

door actuators in the ducts. I believe there are 3 up front. Might want to try to reset the system to see if that helps. They are a known problem.

faster wear on the front end componets. Thats all.

either turn the bolt around or use 1" wheel spacers.

5.5 inches and yes you can with 1" spacers.

The alignment shop guy is full of crap. I put 1.5" spacers on the rear of mine and adjusted to level and got new 35x12.5x17's STT's on my Tahoe now. No adverse steering at all. Just a little trimming of the plastic and no rubbing at all.

Timbren bumpstops will help.

No. Front is adjustable by the preload on the torsion bars. I have RC keys and 1.5" spacers in the rear.

Aint gonna hurt anything cleaning the TB. But there is a lot to fuel mileage than just a clean TB. Spark plugs, O2 sensors, heck even winter vs Summer fuel blends will affect mileage.

Yep, wheel bearing. If you havent replaced it since 154K and you in the 190's now, you def got your $$$$ out of them I had to replace both of mine before 100k. If one side is bad, better replace both. And get quality bearings, like timkin. Autorock has them for just over $100 each.

Just adjust them as much as you want. If you lift or lower the front more than 1 inch, have it aligned.

I believe I was told once that 1" the stock shock was fine, but 1.5 and you'll probably need new, longer ones. So take that for what its worth.

What steering sensor are you talking about? Never heard of it.

Depends on what you needs are. I use cooper discovery St/maxx tires cause I'm offroad a lot but not into serious mudding. I mainly need good traction for slick boat ramps and nasty unkept dirt roads.

Glad you found the problem. BTW, did the shop at least give you a kiss after the labor charge for both plugs and wires? I'd complain about that one.