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My rebuild (some humongo pics)


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It's an '86 2.5L, with the 904 automatic, and NP207 case.

 

I bought it for $100, and was told the transmission was the only thing needing replacing. I got it home, threw it on blocks, pulled the tires, and said, "oh, crap."

 

Now here's what it was, what it has become, and what it is becoming put chronilogically.

 

How I got it:

 

The outside:

Front axle (Dana 30):

Rear axle (Dana 35)

The inside (I cleaned the inside before this):

Real gauges!

Old, bald, mismatched tires on aluminum rims:

No bumper and some banged up trim:

Old deck (broken):

Rock rails and disconnected exhaust:

Factory 2.5L (inspecting with the valve cover off):

The front end:

The rear end:

The old tranny:

New tranny, but old t-case (which I'm using):

The extra rims I got, but am not using. Maybe for winter tires or somethin:

Crappy wires!

 

 

FUDGE!!! Piston number 2 has holes in it. Big time valve damage. Shocks are blown (one into two pieces)! Time for new suspension...

 

Unknown brand of 3" lift coils:

2" lift shackles (welded flat bar on):

Screw you, old motor!

New motor (in corner), you are beautiful!

God hates you, old motor!

You are a mess!

A lil cleaned up under the hood:

I like this (Mmm XTerrains):

 

On all fours! jamminz.gif It's up 2" in back, and because of no engine, tranny, t-case or hood, about 4" in front. 1.25" spacers'll go in once all that's on, so it'll sit about the same hopefully.

 

The rails (still in need of paint):

Still no front bumper!

And my spare:

 

 

The old engine finally gets the head pulled. What have we here?

 

 

 

Well, well, well...

 

The new guy. Pretty much put together here, but missing a couple things here and there.

 

 

Hmm... We need some electronics. Let's start with these!

 

MTX 12"

JBL GTOs (6x9s for the doors that got cut):

820 Watt amp:

Obcon box (match made in heaven for behind my bench):

 

 

I've got a nice MP3 deck I'm pulling from my GMC for the Comanche, but don't have any pics of that. Also, somewhere in there I got a new radiator. It's of the black variety. I dunno what else.

 

I need fixed adjustable LCAs still, and have gotta do a bizzillion more things, but the engine and trans are now mounted!

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  • 1 month later...

Okay... It's almost done. Engine and tranny are in.

Here's my list of crap to still do, in a random order:

 

fill water

fill oil

fill tranny

fill t-case

fill front diff

fill power steering

install 1 water fitting

ground motor

mount battery

make intake tube

install down-pipe/cat

cut smashed tailpipe

mount new LCAs

modify trackbar mount

modify sway bar end links

box shackles

glue up headliner

install wood headliner

stop PRNDL tooth from breaking off everytime I put the wheel down

get windshield replaced

install rear window latch

fab front bumper

registration

install u-joints in driveshafts

starter

inspection plate

stereo install (at shop)

alignment

mount hood

connect shift linkage

install t-case

paint rockrails and rear bumper

fix passenger armrest

spare mount

 

And then this buddy's done!

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The fruckin engine runs!!!!!!!!!

 

The truck doesn't move yet, but the engine runs.

 

Here are the new problems or quirks:

 

*Truck won't start in Park, but will in Neutral. Think I have to adjust the shift linkage.

 

*Headlights only work on highbeams. Might be bad lamps.

 

*Front blinkers and front running lights don't work, but rear blinkers, rear running lights and rear hazards work. Maybe bad bulbs.

 

*Oil Pressure gauge is a freak. 40 to 80 sparatically. Bad sending unit?

 

*Cargo lamp doesn't turn on, but the light on the button does. Bad bulb again?

 

*B-Pillar lights don't turn on, but lights on the floor do. Maybe bad bulbs again??

 

*Instrument cluster lights don't turn on. This I think is because a bunch of fuses are missing.

 

*Lots of missing fuses. Didn't look at which ones. I'm beat.

 

 

This week I'll do the suspension, get the windshield replaced, and register it. This weekend, I'll press the new u-joints in, and DRIVE this mofo!

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x2 on the grounds.

Par particular attention to the front bulb sockets.

They're a stupid design that lets the ground in the socket corrode.

I fixed mine by cutting down one of the wife's emery boards to fit the little hole on the side (behind the gasket), and using that to clean up the mess of green copper corrosion down there. I then spray it full of oxgard. Been fine for a year now.

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I drove that mofo from one garage to another tonight, and stained my seat with splooge.

 

Anywho, tomorrow's plans:

deal with short track bar issue

modify axle side LCA mount

box shackles

new muffler

 

The fixed arms I bought hit the axle at 4.75" of lift, so I'm gonna cut away some metal till I can go long arm when it warms up in the spring, and running the truck I realized the muffler is completely blown out, so I'll pick up a MagnaFlow in the morning.

 

 

 

Umm... My front axle housing is bent... The PO somehow bent the housing while running the truck stock...

 

I need a replacement Dana 30 with 4.10:1 gears. Are there any suggestions on where to get one? I was thinking a 4 cylinder TJ, XJ, or MJ would be the vehicle to look at.

I'd like to keep the vacuum disco and what not, so as to not modify much.

 

 

And I've got some sort of vacuum leak that is lowering my idle, keeping my 4wd light on, and making my heater blow at a low speed. Grr.

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I would be out cruising the town right now, but...

 

DMV was never notified that the original loan on the truck (in 1986) was paid off, so I need to get a signature from the bank in which the loan was taken from, saying that they are no longer a co-owner of the vehicle, so I can register it.

 

$#!&ty luck, but I drove it today anyways.

 

This is how it sits (needs a bumper badly):

 

The Manche's back up a bit, but it's still absolutely dwarfed by my dad and brother's Super Duties.

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Umm... My front axle housing is bent... The PO somehow bent the housing while running the truck stock...

 

I need a replacement Dana 30 with 4.10:1 gears. Are there any suggestions on where to get one? I was thinking a 4 cylinder TJ, XJ, or MJ would be the vehicle to look at.

I'd like to keep the vacuum disco and what not, so as to not modify much.

 

 

How'd you determine that?

 

The XJ/MJ/TJ/ZJ/WJ axles will all bolt in. Vac-disco was done away with in 92 I think, narrowing it down to XJ/MJ axles... Personally I'd get rid of the vac disco, as all you have to do is pull off the vacuum lines that go to the tcase and throw them out/cap them as needed. You'll lose the indicator light.

 

Then any newer 4cyl axle will work. Look for one with 297X u-joints.

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The camber is totally f'd?

 

 

That's a set of bad unit bearings. And possibly ball joints...

 

The camber, yes, but also the axle itself looks physically bent.

I'll snap a pic tomorrow after class so you can see or correct me.

 

I have to bring it to a mechanic shop to have them sign a paper verifying that the engine is installed properly. Maybe they can check somehow.

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The Manche's back up a bit, but it's still absolutely dwarfed by my dad and brother's Super Duties.

 

i know exactly how u feel my parents own two superduties and everytime i see my truck next to them it looks like its getting smaller

 

5" of lift and it's the same size as my bro's stock Ranger. Seems like the truck is tiny! Feels smaller inside than my Yota for some reason to.

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