Completed Project Kirby's Navajo Next Level

[BKennedy]

No thats cool! I was just kidding! That is what this is for. No problem. Ask away.

I updated my sas thread with new pics since the links were all dead.

We were both kidding. I am thread hyjacking advocate. :
I went through both of your SAS threads and they were very helpfull. Extended length radius arms, FW D44 with the wedgies moved in to match the frame width of the Explorer, and coil overs for me. Now, if I can just scrape up 5-7k, I will start grinding.
Until then, I will keep what I have and hope it does not break before my off road budget is expanded.

 

[Kirby N.]

We were both kidding. I am thread hyjacking advocate. :
I went through both of your SAS threads and they were very helpfull. Extended length radius arms, FW D44 with the wedgies moved in to match the frame width of the Explorer, and coil overs for me. Now, if I can just scrape up 5-7k, I will start grinding.
Until then, I will keep what I have and hope it does not break before my off road budget is expanded.

It is somewhat nice when it comes out of neccessity. When I broke another hub and a locker in my Dana 35, I took out the center section and ran it empty. Because I was able to sell it, I could get started on gathering parts. Then it was like I had to get it done if I wanted 4x4 again. The Bronco I built had the TTB in pieces from worn out parts and abuse, so it was out of neccessity too. You may find the motivation/ funding when your TTB breaks 1 too many times! Thats what it took for me. Of course it wasn't nice when the parts broke, but looking back on it that is what it took.

 

[Kirby N.]

OK, so the Navajo is getting some more work due to breakage. It is that whole "it is somewhat nice" because I finally have to put some much needed wrench time in it, but right now it sucks! Easter Jeep Safari is April 12. My wife and I are going and I hope to drive the explorer.

Carnage? Last sunday I was trying to show this guy up in his 86 bobbed 4 runner with a Iforce tundra V8 and Dynatrac ProRock 60s. My clutch smoked like never before and one the way home it was aparent my tires were not breaking loose and my clutch was toast.

So, I am considering buying a a centerforce and the doubler needs to go in. $300 sucks. I got the 1350 case, and I got started on it. I also ordered up the shift nobs from the toyota place. I need to order the shift boot.

Easter is the deadline, or I have to drive the JEEP to easter jeep safari!!

 

[Kirby N.]

I have been researching the doubler. It looks like you can switch from the 6 gear 1350 planetary to a 1993 or later 1354 6 gear planetary, sun colar and shift fork- straight swap. I am considering doing this, but it is only going to cost more money and take more time!

 

[IZwack]

What is the advantage of switching?

 

[410Fortune]

oooh build me one build me one! LOL

doubler = whole new ball game on the trail for you! I remember the look on HVAC's face in Moab when he first installed his Atlas T case (tractor gears) he climber right up rock chucker like it was nothing. You are going to have the same look wheeling before doubler and after doubler is like going from open to locked!

 

[slammer67]

Nice build, I've been watching it for awhile now.

I have done the swap to 1354 planetary/shift fork/slide collar on my doubler and it does work. The 6- gear 1354 planetary is supposed to be way stronger than the older 4-gear set, Plus the 1354 shifting setup is alot better design. I was having troubles with my 1350 doubler popping out of gear due to the plastic shift guides wearing down. I swapped in the 1354 setup and it's working great so far.

You're in Springs, huh. Lets do some trails. I should have my truck done soon (need front R&P gear setup) I want to do Mt. Blanca when my trucks done.

 

[slammer67]

Oh, and about the clutch, centerforce is awesome, but I got a kevlar disc and pressure plate from Pueblo Brake & Clutch for like half that and it worked well- for awhile, then I pulled out the m50d and put in a c5.

 

[410Fortune]

dang rig sounds sick!

 

[Kirby N.]

Ed ordered me a centerforce today. I am pretty psyched. I also got a centerforce thowout bearing, and little heims for the shifter linkage.

Jaime- I can't wait for the doubler. It has been sitting on the shelf for a year, so it is about time. I talked to a clutch shop in the springs about my clutch drag issue. I mentioned to them about the spacer behind the flywheel idea. They said explorer clutches have 1/2" extra throw, so it shouldn't be an issue. None the less, I mentioned it to a mechanic friend of mine and he said your idea was feasible and due to the fact that I machined this flywheel once (and no telling how many times ryan did). So I think I am going to put in a new flywheel. I got one for $65, so I think it is worth the peace of mind. The clutch shop also said 2 things:

1. clean the splines of the input with sandpaper until the disk slides on like butter. He thinks the disk is binding and that is causing it not to release.
2. bench bleed the master. Take out the master, put it in a vise and bleed it before even attempting to bleed the slave.

both of these seem very plausible to me. When I swapped trannys I put in a new master, slave and hydro line, so I could see some air being trapped in one of them. The clutch seems like a very stiff pedal too.

I have alot to do. The case is getting tig'd tomorrow. I have to finish cutting it and cleaning it up. The guy who is doing it is pretty impressive. I saw a magnesium motorcycle hub and a aluminium radiator that he fixed and it was beautiful.

 

[Kirby N.]

Nice build, I've been watching it for awhile now.

I have done the swap to 1354 planetary/shift fork/slide collar on my doubler and it does work. The 6- gear 1354 planetary is supposed to be way stronger than the older 4-gear set, Plus the 1354 shifting setup is alot better design. I was having troubles with my 1350 doubler popping out of gear due to the plastic shift guides wearing down. I swapped in the 1354 setup and it's working great so far.

You're in Springs, huh. Lets do some trails. I should have my truck done soon (need front R&P gear setup) I want to do Mt. Blanca when my trucks done.

I am always up for wheeling. I agree with you on the strenghth and the shifter setup. I would like to do it, but it depends on whether I get enough time to make another junkyard run or not I still have to move my gas tank, get my driveshafts lengthened/ shortened and build a crossmember. I feel like I maybe cutting it close come april.

Are you doing your own R/p? Do you have parts yet?

 

[410Fortune]

welding aluminum or magnesium is a PITA, guys worth every $$$$

bench bleeding your master cyl must be done in the truck now that its mounted, the plunger only goes into the body one time, it wont come back out

I bench bleed the master and hydro line BEFORE I hook it up to the slave cyl
I determined after every possible type of bleeding that it was NOT air in the system
It was powerbled, I raised the back of the truck up about 4' and bled, I bled the master and the line first, then the slave, etc etc there was no air in there, clutch just doesnt release fully, you can see it through the inspection cover 1/2" extra throw or not.. your explorer clutch is hooked to a BII master cyl, I believe this is where the problem is, shim the slave cyl closer to the engine is my idea!

I ran a shim behind the flywheel, then two shims, then a new flywheel, same issue

 

[Kirby N.]

I bought a new master cylinder and slave and line. I believe I bought them all for a 93 ford explorer when I originally did the swap. I tried it with the master that I got from brett, but it seems like there was an issue or something. Maybe the thread I wrote up about it would tell me. If it is that, I could just buy a new master and be done. It would be rad if it was only that. I need to go look and see if that master looks newer or older.

 

[Kirby N.]

So it is only possible to bleed the master on the bench once?

 

[BKennedy]

I was told by Winter (aka; SpotterGuy) that a 76/78 master from a F-150 will fit the Explorer and takes care of any brake issues with using the larger D-44 brakes.

 

[Kirby N.]

My brakes are good! I am talking clutch master cylinder.

 

[Kirby N.]

Jaime- I looked at my old threads and there are 2 places I say I used a new master, so I think I did. From my thread and memory I think there was a clip stressed on the b2 one and that had something to do with me getting a new one. Then the hose wouldn't work with the new one so I had to get another hose from the dealer, so I am sure it was new. I may see if I have the reciept and see if it has a warranty. It may be worth getting another and bleeding it on the bench first even if I don't have the warranty.

 

[410Fortune]

I hope you get this fixed! It was so frustrating for me I went to an A4LD of all things! LOL

 

[BKennedy]

My brakes are good! I am talking clutch master cylinder.

I knew that, I was just testing you!

 

[Kirby N.]

I hope you get this fixed! It was so frustrating for me I went to an A4LD of all things! LOL

I have to admit, that is seriously frustrated! Part of it that is so baffling is hearing you struggled with the same thing. It makes me wonder what is the common denominator (maybe it is that we both drive 4x4s that come with questionable trannys!)!

I knew that, I was just testing you!

So I passed?

I am going out to finish cutting up the doubler. It is getting welded at 10 tomorrow. All this fuss about pickling the aluminium- my guy said we would just preheat it and it would be fine. I am looking forward to learning all about tig'ing tomorrow. I have had access to a tig machine, but I hear that it is so hard that I have been intimidated!

I will post pics when I am done with the pre welding prep.