Betty's "I want to be a mule" progress log thread

The new turd mobile. 2000 Mountaineer v8 awd.



The bad:

Was living it's prior life on a dusty road. Must tear out interior and deep clean.
Driver window off track "or something" and will not roll down. It tries but the rear part wants to stay up.

3 out of 4 door handles have issues. I have 4 new outer handles on order.
Cracked passenger side tail light housing. ( Ebay for some cool tail lights)

Compass-Thermometer thingy lit up and went out--idunno bout that yet

Door locks seem sticky, probably has to do with the handles.
It has a funky purple color trim with red metallic ( you'll have that every now and then)

The good
Gas tank was full
109k miles
I am the 2nd owner!!
Is from the local area, which means no salt!
The undercarriage is fairly clean
No dents to underside panels
Good rubber
Camber shims already installed
Looks like good service records, all recalls were completed.
Clean carfax believe it or not.

The "maybe" bad

The original owner, told the dealership it had a bad "heater core" however I have run it for several cycles, over an hour each idling in the driveay and see no leaks.
However, there was evidence of a windshield leak or the like,I saw condensation on the inside of the windows this AM. The moisture smell is that of water only-no anti freeze smell. I am thinking it could also be a cowl drain which is clogged???? but she did say the passenger carpet got wet.

I tried to get heat, however it is an auto climate control. Being 90 degrees outside, I doubt it would have given me heat.The heater core hoses were hot, and the coolant bypass valve does operate. AC blows Ice cold.

Maybe she meant to say "heater door"???

Anyway--here are the pics.



My intent is to drive this and use it as a tow rig for a light weight off road toy. Mods will be minimal. Edit: This plan did not work out so on to plan "b"

Current visual status

Progress pictures

Now, let's clean it up a little


Herculine'rd rocker panels. Rock sliders installed

BW 4406 True 4x4 Manual transfer case ( AKA Mouse entry point) installed 8-27-2012
Installed newer Tcase from a 2003 11-14-15

Saw a rainbow in Colorado so yeah, time for a picture

And here she is, on top of the highest pass road in North America. Careful tire placement a must!!!

2-2-2013

Changed "color scheme" of the Dick Cepek DC1 wheels. New Falken Wildpeak AT 31x1050x15

Then I decided Maroon washer on the wheels would look better

Update 6-6-2013

New bumpers, winch and Pro LED light . Front Bumper from RLC, Skid plate from RCI, rear bumper from Kert307

Rear anti sway disconnects

Update 9-2-2014
A cracked radiator at 70mph led to engine failure. Replaced with a freshened up a bit 80k mile engine starting on page 23

Found another rainbow in Kansas.

 

[Turdle]

I thought before I tore it all up I would shoot this video. You can now plainly see the axle shaft is bent. Look at the side to side movement of the caliper. I walked to the passenger side so you could see it spinning true.

That would explain the premature pad failure on this side.

I am so glad I caught this, I bet this is where our fuel economy went.

Forgive the air compressor kicking on.

 

[Turdle]

Pictures so we all know I tried to get that stubborn bolt-

The new bolt. It is very upset now, because I am putting it back on the shelf-

And this is going in.

I'll pop the cover and change the fluid once it is in the truck

 

[Brian1]

Are you 100% sure the axle is bent? I had that EXACT same thing happen on a friends F150. I found the problem was the rotor not seated flat against the axle flange. It was hanging up on a wheel stud so since it is a hubcentric rotor we just enlarged the lug holes slightly. You may have a similar issue or a pebble or dirt stuck in there.

 

[Turdle]

Are you 100% sure the axle is bent? I had that EXACT same thing happen on a friends F150. I found the problem was the rotor not seated flat against the axle flange. It was hanging up on a wheel stud so since it is a hubcentric rotor we just enlarged the lug holes slightly. You may have a similar issue or a pebble or dirt stuck in there.

Pretty sure, this is the same brake that was chewed up earlier. I replaced the rotor

Old axle out, "new" one is siting on the leafs.

 

[Turdle]

Well, poop. I was going to use the new axles emergency brake shoes but they exploded. So, yeah.
I absolutely loathe doing brake shoes with the axles pulled, let alone with them in the housing.

So, this time I smacked the wrench with the palm of my hand and the center pin bolt popped right loose, just like it should. I've removed that bolt several times. I suspect the diff-axle I pulled out has an issue.

The "new" axle is a lot tighter and smoother feeling. C clips and shafts came right out.

I do have the new shoes and new hardware to stick in. Tomorrow.

Oh, I was able to save the rear disc brake system as one part, it's hanging by hooks waiting to be put back into position.

Looks like I get to use the new center pin bolt after all.

 

[rizzjc]

.

Oh, I was able to save the rear disc brake system as one part, it's hanging by hooks waiting to be put back into position.

Looks like I get to use the new center pin bolt after all.

That's what I did too.

 

[Turdle]

Here's a tech tip for ya.

If you wait until after noon to work on your vehicle it might take all day to finish.

Feeling kinky-- and not in a good way.

 

[traveler]

I learned long ago that unless it's a simple "in and out" job like brake pads, a belt, etc. plan on taking all day. But then I never do get started till after noon. LoL

 

[Turdle]

Old nails and clips used because these are poop.

 

[Turdle]

Welp,
Got it all back together now. The slight "wha wha wha "sound has been eliminated.

I used the same rotor on the same side, and no more wobble.

I still have a slight vibration at about 60 mph but it is a fast-drive shaft related vibe. I am going to rotate the rear drive shaft 180 degrees and re mount it in hopes that cures it.

 

[ahodges]

Post back and let us know if rotating the drive shaft helps. I have a similar vibe north of 70mph.

 

[Dan Whitaker]

288421[/ATTACH]

Yea the new ones are a pain in the ass to use. Unfortunately when I did the brakes on the wife's 2002 Tracker I had to use them as all but one of the original clips broke.

 

[GRNMACHINE]

Thanks for the info and the video Jon. Learn something new here everytime I am on it!

 

[Turdle]

Welp,
Another glitch. Well, ongoing glitch

Still getting a slight "bump bump" in 4wd on wet pavement, straight line under slight load.
I already tried a 2nd front diff housing, and 2nd set of cv axles. Stuck the stock axles back in to the 2nd diff and still have the thud.
I took the front drive shaft off , serviced it all up by greasing the slip yoke, clocking it 180 degrees off, and greasing the double cardaan, and still think I have the thud. The front u joint ( shaft to diff) does seem a bit tight-with a slight snag but no way is it binding enough to cause this thud thud.
The Double Cardaan feels tight and smooth.

It sounds like a skipping thud, like the chain is slipping, or something is slipping it in and out of 4wd.
Stang5lgt told me via FB it may be a worn bushing inside the transfer case causing this.

So, I need to source a 2nd manual shift 4406 transfer case. That way I can stick it in here, and, continue to drive while I rebuild this one.

 

[mr cribb]

Not much. Just some cool chairs. My dad had them stashed away from way back, when they purchased their 92 explorer, and then the 99. He wasn't sure which chair(s) came with which truck though.

Thanks Dad!!

Sorry for the lack of updates other things have gotten in the way. Back in a minute.

I have the smaller explorer chairs bag and all. I found them in the least likely of places. No not the junkyard, but at a Goodwill in Nashville, TN. I think I paid $5 for them.

Nice rig. When funds allow I will be on the hunt for a gen 2 2wd v8. My goal for my next rig is for a v8 5 speed truck. I had these thoughts for my existing gen 1 but I read a very important rule from forum member Nick26 "It is much easier to eliminate electronics than to add them".

 

[Turdle]

I have the smaller explorer chairs bag and all. I found them in the least likely of places. No not the junkyard, but at a Goodwill in Nashville, TN. I think I paid $5 for them.

Nice rig. When funds allow I will be on the hunt for a gen 2 2wd v8. My goal for my next rig is for a v8 5 speed truck. I had these thoughts for my existing gen 1 but I read a very important rule from forum member Nick26 "It is much easier to eliminate electronics than to add them".

Would you believe, my wife now claims the chairs as "hers"

OK, good news ! Looks like the transfer case is not the issue. But WTH is the problem here?

 

[rickybobby]

looks like maybe a bad mount bushing on the front diff, or a bad motor mount

 

[Turdle]

looks like maybe a bad mount bushing on the front diff, or a bad motor mount

Well, today I woke the ol' gal up to go for a spin on the fresh snow we got overnight. 4wd operation was normal, everything worked great and it was a pretty good time all in all.

Man, these Falken tires bite pretty darn good. I'm impressed!

Even on the slick stuff they dig and and pull you through a turn.

 

[gmanpaint]

Things that come to mind on the thud are:

Cracked Trans mount bushing.

Worn or missing T-bar pads.

Slop in the LCA T-bar holes.

Worn LCA bushings.

U-bolts misaligned or loose.

Bad leaf spring bushings.

Cracked leaf spring mounts.

5th shock mounts (if using it).

4406 itself or the shifter hitting the tunnel when torqued.

As Jessi mentioned, the motor mounts.

One obscure item that always gets over looked is the front inner double C shaft joint. This is tucked inside and out of sight, and you can't see it unless you dismantle the entire C section from the shaft itself. Drove me crazy trying to run down my thud on the 95. But this is what the issue was.

 

[Turdle]

As a matter of fact, I am suspect of u joints. Sheri and I were discussing this very thing last evening.

I do intend to replace all 5 of em. Problem though, I do not know which sizes I need. Both shafts are "custom" and without tearing them out to measure them I am at a loss what to do about it.

I "think" I have a expedition rear drive shaft, I know the front is a double "C" --I assume the front yoke joint to be the same as Explorer. I would assume the Double cardan unit is from an explorer.
I would actually enjoy looking up the part numbers if I knew what to look for.

[MENTION=165306]Stang5lgt[/MENTION] Help?