Progress, hahahaha well not really.
Work on the Ex has been slow as of late, I need more $$$ for parts (this Friday.
But I am actually getting VERY close, just a couple days of work and fluids once I have the new E-303 cam, waterpump and timing set installed.
Also need some TM headers.
One of the things I needed to do and was dreading was replacing one of the relay boxes on my project 96 (blue truck). the relay box on the front pass side was damaged in the wreck. The previous owner just let it hang there for some time. The box itself was missing much plastic, the top and bottom covers, and also the bracket. So I pulled the parts off my wrecked 96.
I had two choices., I could swap this box, or I could swap the entire wire harness.
I planned to use the entire harness from my wrecked 96 because it has half the miles on it, however that harness received more damage from my wreck then the blue truck. So instead I just swapped the relay boxes. This info would be useful to anyone working with this or other similar power distribution boxes:
First the damaged box:
And the "new" donor box:
You can see how these boxes come apart. First You remove the rear access cover, it is held in place with 4 small plastic tabs, unplug the relays/fuses and remove the top lid.
Next the red "keeper" is removed by unlocking two lock tabs from the back side of the box.
Once the keeper is out you can remove each individual wire by unlocking it's locking tab.
You see each wire has a metal end, the metal end is held in place by a plastic tab that locks into it. The Red (or yellow) keeper then once locked down holds all the plastic keeper tabs in place, so wires cannot be pulled out or pushed in when you plug in relays/fuses.
Here is the box half way apart:
Now I chose to do this with the two boxes next to each other, one wire at a time. Doing this ensures I get each wire swapped over from the old damaged box to the new one and I cannot really screw up the wires position. If I was to get it wrong it would be a HELL of a time to find the problem later. For larger projects I will take pictures and make diagrams. Not required for this small 4 relay box. During the swap:
And finally the new box in place, all wires installed, keepers back in place, relays plugged in and access covers re-installed.
Now the reason I kept putting this off is it is very time consuming. Tis swap took me about 2 hours total.
You need to have lots of light so you can see the little plastic tabs.
If you are not careful you can break them and then the wire will not lock in place.
The locking pins are very small and also down deep, so it takes some patience and the right tools. I have a small dental pick I use to get the tabs. You have to use one hand to tug on the wire while the other hand unlocks the tab. Some wires take 2 seconds, some you can fight for 15 minutes.
This kind of work makes my hands cramp up so I also have to take some breaks.
Anyways I know its not much but at least I got something done on the Ex this weekend! hahaha
TO DO:
BIG updates coming soon, should be running by March with cam and headers.
I will then swap the 8.8 out for the one from my rolled truck (half the miles).
install my Rancho RSX shocks from the other truck, install new/used airbags and sensors., etc.
She will be ready for paint and a widnshield before April is my goal.
Then the body lift comes off
