20180804_131624.jpg
119 hits | 77.19 KB | Posted: 9/29/18
Even with a visible oil leak, the underbody is fairly clean.
(Posted in: Main)

20180804_181706.jpg
236 hits | 55.83 KB | Posted: 9/29/18
Rear frame horns have factory holes for a hitch receiver.
(Posted in: Main)

Eng13.jpg
110 hits | 106.49 KB | Posted: 9/29/18
For its age, miles, & maintenance history, it looks surprisingly good (after a few rinses).
(Posted in: Main)

Eng05.jpg
107 hits | 66.51 KB | Posted: 9/29/18
The engine oil leak isn't coming from the valve covers, so it's either the rear main or the pan. Both could be done in-chassis, but it's not much extra work (after the timing belt) to lift the engine out & do a much-better job.
(Posted in: Main)

20180804_131827.jpg
125 hits | 77 KB | Posted: 9/29/18
The battery terminals need work.
(Posted in: Main)

20180926_192424.jpg
193 hits | 83.51 KB | Posted: 9/29/18
After blasting the dust off, both rear brakes look OK.
(Posted in: Main)

Tired.jpg
210 hits | 79.97 KB | Posted: 10/4/18
These tires still have tread, hold air, and are wearing evenly. But they're dangerously old (7 years) and beginning to crack.
(Posted in: Main)

Tennex.jpg
201 hits | 63.52 KB | Posted: 10/4/18
The fuel filter might be original.

From here, the Big Fix began...
(Posted in: Main)

20180804_131742.jpg
102 hits | 61.39 KB | Posted: 9/29/18
The rear wiper blade was gone, and the sprayer nozzle was loose. Both were replaced with new.
(Posted in: The Big Fix)

20180805_145222.jpg
119 hits | 87.71 KB | Posted: 9/29/18
While gluing the rubber seal back onto the wind fairing (with a tube of black E6000), I blasted the debris off the roof.
(Posted in: The Big Fix)

20180806_144717.jpg
117 hits | 78.95 KB | Posted: 9/29/18
The cabin filters appear to be factory - even beating them on the concrete, NOTHING came out of them.
(Posted in: The Big Fix)

20180805_132739.jpg
111 hits | 75.57 KB | Posted: 9/29/18
The original speaker suspensions had deteriorated with age, but I had some used ones in my junkpile that fit.
(Posted in: The Big Fix)

20180810_103830.jpg
102 hits | 87.65 KB | Posted: 9/29/18
This grille was relatively inexpensive from eBay, and easy to install. While it was out, I changed the headlights, too (also from eBay).
(Posted in: The Big Fix)

20180821_164838.jpg
115 hits | 71.82 KB | Posted: 9/29/18
I wasn't sure how hard it would be to find or remove a factory receiver in a junkyard, so I ordered this new one. The next day, I found one in the first JY I went to.

The new headlights are noticeably clearer.
(Posted in: The Big Fix)

20180821_174454.jpg
126 hits | 61.29 KB | Posted: 9/29/18
This folding cargo tray came from WalMart. I also put a set of ratchet straps on it & the roof rack. Later, I had to bend the tailpipe slightly to keep it from rattling against the receiver.
(Posted in: The Big Fix)

20180810_143736.jpg
113 hits | 99.76 KB | Posted: 9/29/18
This dual USB power socket is wired to the cigar lighter. There's also an FM modulator with iPhone fire connector up front.
(Posted in: The Big Fix)

20180810_173953.jpg
112 hits | 60.54 KB | Posted: 9/29/18
I found a replacement armrest on eBay.
(Posted in: The Big Fix)

20180810_124336.jpg
121 hits | 100.96 KB | Posted: 9/29/18
The passenger seat wouldn't slide fully forward, and eventually I found there were several coins trapped in the rail. The only way to get them out was the same way they went in: gravity.
(Posted in: The Big Fix)

20180808_163639.jpg
137 hits | 74.84 KB | Posted: 9/29/18
I cleaned the original negative cable & soldered a new domestic-style terminal on. The cable was barely long enough. I also polished its body & block terminals.

The positive terminal got disassembled, wire-brushed back to shiny metal, greased, and...
(Posted in: The Big Fix)

20180806_181353.jpg
160 hits | 84.62 KB | Posted: 9/29/18
Changing the reservoir's fluid doesn't change it all, but it's a start. If this is done during each brake service, the old fluid will never be a problem.
(Posted in: The Big Fix)

20180912_174345.jpg
1057 hits | 97.39 KB | Posted: 9/29/18
To make turning the crank easier, I changed the timing belt in-chassis. I did the water pump & front main seal at the same time. The seal was a BEAR to drive in...
(Posted in: The Big Fix)

20180920_165526.jpg
160 hits | 128.54 KB | Posted: 9/29/18
With the compressor flipped, the bottom of the high-pressure hose was visible, showing dye. So I ordered this replacement. The refrigerant had already leaked out, so I swapped the hose later during reassembly.
(Posted in: The Big Fix)

20180922_144344.jpg
278 hits | 110.71 KB | Posted: 9/29/18
After pulling the upper intake, several hoses & wires had to be disconnected in preparation for pulling the engine. One of the heater core nipples broke, creating a new problem to be fixed...
(Posted in: The Big Fix)

20180923_191720.jpg
147 hits | 86.39 KB | Posted: 9/29/18
Even after a week not running, there was still wet oil at the top of the bellhousing, running down the separator plate.

The white sealant on the pan gasket is not factory, so this pan was certainly re-sealed before. It appears to have been done in-...
(Posted in: The Big Fix)

20180924_111444.jpg
258 hits | 103.6 KB | Posted: 9/29/18
I used a lifting plate I made for a Ford 5.8L (with 3 new holes drilled) to pull the engine by the lower intake, using the plenum bolts & washers.
(Posted in: The Big Fix)

20180924_111458.jpg
152 hits | 97.29 KB | Posted: 9/29/18
What a nightmare! But it's out...
(Posted in: The Big Fix)

20180924_125524.jpg
217 hits | 83.13 KB | Posted: 9/29/18
The rear main had been driven in too far, so it was easier to pull that housing than try to dig the seal out. While it was off, it was easy to polish the grime off the crank hub and check for a wear groove - there was none.
(Posted in: The Big Fix)

20180924_182153.jpg
146 hits | 59.34 KB | Posted: 9/29/18
It only took 1 of the 2 supplied bags of RTV to seal the oil pan, and I let it dry overnight before dropping the engine back in.
(Posted in: The Big Fix)

20180927_151215.jpg
127 hits | 122.5 KB | Posted: 9/29/18
To access the broken heater core nipple, the evaporator had to come out. Since the refrigerant was already discharged, these lines could be disconnected.
(Posted in: The Big Fix)

20180927_151419.jpg
142 hits | 73.26 KB | Posted: 9/29/18
It was surprisingly easy to yank the evaporator housing out of the dash. Probably ~45 minutes, including reassembly.
(Posted in: The Big Fix)

20180927_153054.jpg
206 hits | 95.37 KB | Posted: 9/29/18
I got a used heater core with nipples from eBay, and just swapped the broken nipple.
(Posted in: The Big Fix)

20180927_153149.jpg
202 hits | 98.42 KB | Posted: 9/29/18
I put some Hylomar on the replacement to help the O-ring make a seal, and put it all back together.
(Posted in: The Big Fix)

20180927_180825.jpg
318 hits | 103.17 KB | Posted: 9/29/18
A few hours later, I backed it out to let it warm up & burn off the oil, and to check for leaks. None were apparent, so I used it the next day to run errands.
(Posted in: The Big Fix)

20180928_090347.jpg
196 hits | 62.11 KB | Posted: 10/4/18
It drove fine at highway speeds, and seemed fixed. But at my first stop, an oil leak became apparent - that front crank seal hadn't gone in right.
(Posted in: The Big Fix)

20180930_135007.jpg
201 hits | 94.26 KB | Posted: 10/4/18
I picked up another front main seal, stripped the front of the engine again, and pulled the orange seal out. I could see a chunk missing from its inner lip. So using a tool I made from a blue plastic rebar cover, the new seal went in MUCH more-easi...
(Posted in: The Big Fix)

20180930_141305.jpg
193 hits | 81.98 KB | Posted: 10/4/18
I washed all the belts (including the timing belt). The 2nd seal dripped a little at first, and then stopped. The last thing to fix will be the A/C...
(Posted in: The Big Fix)