My 82 ex-cab...Hydro-Assist questions

[gmack192]

anyone know??   

[82 HiLux]

that header looks just like mine....mine is a pacesetter. i bought it brand new for $140

[82juguete]

Could be...  Well ive been driving the truck around and i knew the alternator was going to need some sorting out.  When i pulled the motor, i ended up with the plug and 3 wire leads comin off the alt.  I thought i had ripped the wires but they actually just pulled out of spades that were hooked up to an adapter of some sort that looks like this:



Now, by identifying the plug shape and wire color, it appears that at one point my truck had a 2wd alternator installed and adapted to the 4wd harness, which i thought wouldnt work due to conflicting regulator issues.  Ironically, charging was one issue i NEVER had a problem with.  But now i have tried different configurations and i cant get it to charge now.  Is my best bet to just get the green wire, offset plug 4wd alternator that should plug right in, and just chuck the adapter setup?

Arent all the partshouse alternators junk?  Any later model toyota alts that are more amps and still plug and play?

[gmack192]

that header looks just like mine....mine is a pacesetter. i bought it brand new for $140

thanks

[83 Crawler]

truck is sick dude! i love white toyotas i think im going to paint mine

but good job on the build 

[SloCrawler]

Nice Build. Hope mine gets amounts, like the details

[82juguete]

Thanks guys... oh i posted in a couple other threads but i threw together some half doors and im loving them....



The new motor is nearing the 500 mile mark, the break in is going well, took care of all the leaks... think i need to fine tune the timing a little still... also need to retorque the head and readjust the valves... But so far everything is good!

[GONZO97]

seems like everything is going pretty well especially after that last trip to mirror, you really got me out of a pickle a couple of times

[cberg]

Looks excellent! Giving me lots of inspiration for my first gen pickup as well. Keep up the good work!

[83 Crawler]

love the truck dude

[82juguete]

driving on the 101, about 20 miles from San luis obispo, doomsday sounds erupt from beneath my truck, it shakes, i pull over and put my hazards on.  What did I screw up on the motor rebuild?  What part or bolt did i forget?  My heart drops and these thoughts flood my mind.  I get out to inspect (10:30 pm on side of freeway)  And fortunately discover that the rear d-shaft dropped.... the T-case side came partially unbolted somehow and the last bolt sheared off.

I always invisioned this type of failure resulting in a catapulting of the rear end of the truck, luckily my theory proved wrong in this case.... damage was minimal, i borrowed 4 bolts from the front shaft, and limped to my apartment.

[83yota]

i have been there but i shot my flowmaster all the way accross i-15 in slc. really scary till you find out what is wrong.

[GONZO97]

ouch thats a scary story. Was driving to school this morning and my truck decided to pull all the way off the road at fifty miles an hour not fun trying to steer it back onto the pavement without losing control. not too sure why it did that. it drove fine last night.

[SloCrawler]

Nice another slo local?

[Talon84x4]

Mine did the same thing with the d-line when I first got it. Loud boom and a thump, then a 2" dent and a small rip in the tunnel

[82juguete]

yea i got a nice dent in my exhaust pipe, and some scrapes on the tunnel... i thought the motor completely blew up by the sound of it!

On another note, after long trips like this im getting alot of oil blowback on the undercarriage.  This time theres a coating of oil on the entire front surface of the rear axle.  Im thinkin its gear oil but cant really check it out right now...  Any ideas what could be wrong that would be leaking this much oil and seemingly spraying it while im driving?

[Slolyfe]

yea i got a nice dent in my exhaust pipe, and some scrapes on the tunnel... i thought the motor completely blew up by the sound of it!

On another note, after long trips like this im getting alot of oil blowback on the undercarriage.  This time theres a coating of oil on the entire front surface of the rear axle.  Im thinkin its gear oil but cant really check it out right now...  Any ideas what could be wrong that would be leaking this much oil and seemingly spraying it while im driving?

just start looking around. Ive had my oil pan gasket, rear motor seal, and rear tcase seal all do that over the last 6 years.

[82juguete]

alright guys, heres the deal.  I am at my apartment currently and unable to work on my rig.  From the smell of things im pretty certain now that its gear oil thats leaking, and the drivetrain is coated from about the back of the bellhousing back... mainly the oil is collecting and running off the skid/crossmember when its parked.

I understand that its hard for you guys to speculate for me, but im wondering if you have any ideas for what seals or joints commonly fail and leak in the t-case area and how time consuming it is to fix.  I will only have a 2 or 3 day window when ill be home and able to address this before im back for school for the quarter...

Just trying to do as much prep and research as i can until i can actually work on it...

thanks

[hilux-1983]

try and post pics so we can see this leak. Make sure there is plenty of light to be as clear as possible.

[82juguete]

sorry i have no camera now and cant get any pics, but i mightve found the problem...

Finally got to investigate and it appears that by the pattern of oil (line across exhaust pipe and underside of floorboard) that the t-case rear output seal is failing big time.

Whats the timeframe involved in replacing it?

This also got me thinkin, if the output bearing is bad, could this be the cause of the seal failure AS WELL AS the backing off of the rear DS bolts, maybe from slight vibration or something...  Also, i have been noticing a slight ticking, almost grinding sound from the drivetrain when im decelerating with the clutch in...could these all be related to one another? 

[82juguete]

correction:it makes the noise when i let off the gas and DONT push the clutch in.  Pushing the clutch in stops the sound.

Oh and great news, my alternator stopped charging on the way home today...barely made it home.

When it rains it pours i guess.

[GONZO97]

sounds rough man i hope it all comes around keep faith its always greener on the other side

[Talon84x4]

A rear seal doesn't take any time at all, but a rear bearing will take a little longer. A case is not hard to go through especially if you print up the walk through they have on this site, I believe it's the crawler installer  

[82juguete]

alright well im going to disconnect the rear DS and check for any play at the output.  If the bearing feels fine and it is just the seal, do i just need to remove the companion flange to replace it, or do i gotta go deeper?

I would just go through the whole case, but dont have the time right now.

[Talon84x4]

I think you can just pull the output flange to get the old seal out and the new one in. If it's not coming out with just the flange off then at most you would have to remove is the rear most cover. Here's the break down: http://www.marlincrawler.com/tech/guide/4701-gear-install

[82juguete]

Well i replaced the output seal this morning, so hopefully that takes care of that.  Now onto the charging issue.

I was confident that the alternator was bad.  I tested with a voltmeter and the battery was at about 12.7v normal but dropped to around 12.4 when i started the truck.  Headlights, radio, etc all lowered this number.  Kragen did an in-truck test which confirmed my results.  So i pulled the alternator and took it in, fully expecting to get a free replacement no question because it came with a lifetime warranty and is only 2.5 months old.

Well the bench test determined the alternator is fine, and putting out about 14.68. Soooooo...  now im trying to figure out where the problem is.. the engine and gauge fuses are good, but i cant seem to locate this "fusible link" that seems to be a common culprit.  So where are they on an 82?  Thanks for any help

[82juguete]

well i think im going to go ahead and replace the voltage regulator tomorrow. In the meantime, anyone have any other thoughts on what it could be?

The weird part is that it worked fine for almost 3 months, and then it just stopped charging all of a sudden.   

[Jud]

Check all the wires that run to the alternator. They could be getting pinched or there may be a loose connection somewhere, or corroded, or something like that. 

[82juguete]

Threw a new regulator in today, looks like problem solved!  I had a feeling something had stopped working since the problem just happened one day, and wasnt intermittant or anything like a pinched wire or loose connection would likely cause..

I should've replaced that with the alternator, but i wasnt thinking   

Oh well, im really glad i dont have to tear into the wire looms trying to hunt down faulty wires or connections.  I'm going to enjoy this, as we all know most solutions don't usually come this easy!   

[82juguete]

Look at this... i DID something!
Scored these civic seats the last time i was home around thanksgiving time... and threw them in today, replacing the stock bench:



They are pretty comfortable, and the swap was super easy, the rear mounts lined up and i just had to redrill the fronts.  Also gave me a chance to clean under my seats and i found $13.62.... sound impossible?  No, there was a $10 bill under there.