Topic: KDXSR5s Wyo DD Build: Starting To Come Together.............SLOWLY

[KDXSR5]

Some hose clamps, some rubber deals from checker, and some 3 inch PVC

[GJToyotabug]

looks good what are you doing for a battery box?

[KDXSR5 [OP]]

looks good what are you doing for a battery box?

I am not sure yet. Checker has a plastic box that i think i am going to use. I plan on mounting it on the passenger side in front of the wheel well and running the cables through the bottom of the bed. Cable routing is below

Positive:
Battery to starter
Battery to fuse block

Negative:
Battery to frame
frame to cab
frame to engine block
head to cab
Maybe frame to bed


If you think i need anymore please let me know... I don't want to have any issues with electrical stuff. I am going to be running either 2 or 4 gauge welding cables because I found a spool of both at the tractor store, and it is pretty fine wire and should work for this. I just need to find the type of cable ends i want and then i can get that all hooked up


I still need to route my snorkel setup but that is not going to be necessary to start the truck, so it may not happen right now

[Duffil]

Looks good brotha. sounds like you got it all sorted out.

[KDXSR5 [OP]]

WELL F@#K A DUCK I HAVE F@#$%&G COOLANT LEAKS

I filled the radiator and I have two leaks... one where the heater hard line connects to the bottom of the lower intake and another one where that short hard line connects to the back of the timing cover on the passenger side. Time to take the whole F@#$%&G thing back apart again

[Cheesemaker]

Is there enough flex in the intake for when the motor rocks under acceleration?  It doesn't look like enough flexible tubing to me.  (From AFM to TPS!) 

[KDXSR5 [OP]]

Is there enough flex in the intake for when the motor rocks under acceleration?  It doesn't look like enough flexible tubing to me.  (From AFM to TPS!) 

If not I will do something else. We will see how it works out.

[KDXSR5 [OP]]

I bought some tires for the ford, $20 for two of them, so I will have the BFGs for my truck hopefully tomorrow. I also started taking stuff apart to fix my two coolant leaks

[KDXSR5 [OP]]

update... I think i have one out of my two coolant leaks fixed. I did the easy one on the back of the timing cover. I am now going to go try to fix the other coolant leak that is up under the lower intake without removing the intake. I have to pull a few hoses and wires and such off, but I think it will be worth not having to take the intake off again.

[KDXSR5 [OP]]

Ok, so I had one bolt in holding the pipe to the bottom of the lower intake, and I started tightening the other one down. And then it snapped. I guess I am really f@#$ed now. I don't even want to look at the stupid POS now. I am going to go for a nice long bike ride possibly into a wall

[KDXSR5 [OP]]

I took a couple pics to show whats up. First pic you can see the broken off bolt. I circled it in yellow. Second pic shows how much of a pain in the ass it is to get to where the bolt is (circled in yellow). I am laying on the ground, reaching up around the diff/axle/driveshaft trying to get this dang thing out. I had to remove the oil filter, the starter, and take apart the fuel filter and fuel filter bracket just to get up in there. I had the thing completely done and sealed up when the bolt snapped. What a pregnant dog.

[GJToyotabug]

oh man sucky well their goes your plain to keep the intake on

[KDXSR5 [OP]]

I guess so... I am going to try and find a drill that will fit up in there, but I doubt I will find one

[Duffil]

damn todd that sucks. sorry man.

but just think of how good you're going to be at this when you're done.

[79coyotefrg]

dude, that efi intake has got to come off, 

[KDXSR5 [OP]]

dude, that efi intake has got to come off, 

Not if I can help it

[KDXSR5 [OP]]

I found a drill that will fit up in there and I found a 1/16 reverse cut drill bit. Lets hope for the best

[Cheesemaker]

That sucks.  I started to use the factory bolts when I was putting all the brackets and such on, until I was stretching some bolts.  Using a torque wrench, on the water line on the other side of the motor, where it bolts to the water pump/timing cover.  At 12 ft.lbs the bolt stretched.    And then I replaced all the bolts with new ones.  Got to remember that these are all over 25 years old, and they have metal fatigue just from age.  I just didn't want to get into a spot that you are now in.  Good luck!

[KDXSR5 [OP]]

I got that broken bolt out without pulling the intake. I used my friends really small drill he got at walmart and drilled a pilot hole with the reverse cut bit, then used a small easy out. Worked like a charm.

[THK Matt]

awesome

[jimbo74]

good

[SolidAxle]

Good work, i would have pulled the intake off because i thought that would be impossible... I pulled the intake off many a time when i first put my engine in.

[COToy91]

More pictures of the bed on my truck here
http://s240.photobucket.com/albums/ff180/kins5402/

[KDXSR5 [OP]]

More pictures of the bed on my truck here
http://s240.photobucket.com/albums/ff180/kins5402/

Thanks

[KDXSR5 [OP]]

Well I haven't been on in a while. Time for a little update. I put the engine back together after fixing that broken bolt situation and no more leaks. Bled the clutch. I then routed my battery cables and such and tried starting it wednesday night. It shot fuel all over out of the rear injector. Off comes the upper intake and fuel rail and a new o-ring goes in. Put it all back together. Try to start it again. Gas shoots everywhere. Cyl 3 injector leaking. Take upper intake off and fuel rail off and call it a night.
Next day I went to checker and bought 4 injector seal kits that come with the 4 seals needed for each injector. Installed those, put intake back on and fired it up. It ran for about 3 minutes then died. Started it back up and got it to run well enough to break in the cam at 1800ish rpm for 20 minutes. Turned it off and started dicking with distributor. Found it it was a tooth off and the engine was running (terribly) at some crazy number like -20 degrees timing. Put it back in on the correct tooth and set timing to 5 degrees. Starts fine and runs perfect now. Called it a night. The oil pressure is a little on the low side. New radiator seems to work really well.
Today I try to pull it out of the garage only to find out the clutch doesn't work. Oh well, at least it runs. So I had a friend come over and we towed it to the schools auto shop. My power steering is going out too. Something is wrong with it and it was going out before the engine swap. I think I will replace all the mystery fluid with some new atf and see if it changes it at all. So currently it is still sitting in pieces at the schools auto shop waiting for me to finish it up next week. Hopefully the clutch is just really out of adjustment. Update out.

Any ideas/constructive comments will be appreciated.

I would like to thank Glen, Rex, Mini, and Josh for their help in getting the truck out of the garage. You guys helped a bunch both with information and motivation boosting. Thanks!

[79coyotefrg]

   now we need  offroadin pics

[Hammerhead]

Are you gettin' excited yet? 



At this rate you'll have it on the road before I finish fixin' the runner... 

[GJToyotabug]

ok since todd left i'll update he's been working his off it's running!!!!!!!! WOOT!!!! he took it down to his auto class to finish all the little details as soon as it started running the PS pump took a crap so he's gonna try and use the 90 pump. soo thats about it if i get pics they will go up here well i'll see ya all later

[KDXSR5 [OP]]

   now we need  offroadin pics

Thanks for the help Glen. You have been a great inspiration for me with your truck. Its just amazing. If you can do that with your current physical situation then I figure I should be able to do anything. Hopefully offroad pics will come before the snow comes.

Are you gettin' excited yet? 



At this rate you'll have it on the road before I finish fixin' the runner... 

I will be really excited once I can drive it! I want to see the runner when you get done with it. If its anything like the old landcruiser it will be really cool.

ok since todd left i'll update he's been working his off it's running!!!!!!!! WOOT!!!! he took it down to his auto class to finish all the little details as soon as it started running the PS pump took a crap so he's gonna try and use the 90 pump. soo thats about it if i get pics they will go up here well i'll see ya all later

I will try changing the fluid first and bleeding the system really well before I look into a pump swap, but if worse comes to worse I always have the 90 pump and I may still have the 88 pump up in the shed.

[unclejpl4x4]