Pugly

[lynchy wa]

Good Stuff!!!

 

[GRNMACHINE]

Pugly Do Right!

 

[gmanpaint]

Flipping the hitch.

Been wanting to do this for some time now, and finally got around to it.

The hitch on Pugly hung too low after the 3" body and looked awful, plus was in the way on the trails, hanging up on stuff. The hitch is mounted in 3 spots and could not just simply flip over and bolt upside down. So cutting and welding was needed.

Before.

The bracket ends were cut off the center tube, then the tube was flipped 180* and welded back together. Broke out the grinder and cleaned it up for paint.

Welded back together, cleaned, & primed.

Couple coats of enamel.

Hitch installed.

All tucked up and looks normal again.

 

[Glen4X4]

Looks great Gregg!

 

[lynchy wa]

Fantastic job mate

 

[gmanpaint]

Thanks guys.

 

[GRNMACHINE]

Super Nice Work. Again

 

[gmanpaint]

Super Nice Work. Again

Thank you.

Pugly needed a better cb antenna installed, and I received a new 4' firestick thanks to the help of cybergasm. The truck stops have better prices than around here, and since he is always at one, he simply picked one up for me. Thanks again!

So....after trying the tail light mount idea, I realized this firestick was just too heavy for that. The mounting bracket just bent and the tail light wanted to break under the stress. So it needed a different approach. I wanted it to be behind the vehicle. It's safer back there than anywhere else on the rig.

I used a 1/4" aluminum shelving bracket that can be found at any hardware store for less than $5.00. Cut it to size and shaped the antenna side with the grinder. Using the holes already pre drilled in it, It was attached to the back of the cargo door. I slid a 1" flexible putty knife under the Explorer emblem, and used the grinder with a cutting wheel to cut out the letter "L". This was the optimum spot for it to me because of the innards of the door. The bracket fit perfectly in the removed letter spot. I used a HD spring on it, and opening the cargo door glass is a breeze. Just have to move it to the side while opening it.

On the lower sides of the cargo door are these plastic gliders. The left side on Pugly was already broken, so I removed it. Behind it is a nice size hole to run the coax thru. I have a box of rubber grommets around somewhere, I will install one after its located.

A 5/8" hole was drilled( to allow for the big coax connector) in 2 places for the coax. 1st was in the cargo door panel on the upper side. 2nd was at the top of the very rear of the left cargo panel. Simply run the coax thru each hole, ( leave some slack so it bends inward and away from the pinch point of the door when closed) and then to the radio.

Still on the hunt for a good deal on a 2nd gen 4:10 8.8 for it. Hopefully sometime this summer the axles will be swapped out. Tripping over the 4:10 D35 in the shop keeps reminding me about that mod. :

 

[lynchy wa]

Sweet mounting point. Well out of harm's way, I alway's cringe when I hear my aerial catch on a bit of scrub. Top job mate.

 

[gmanpaint]

Sweet mounting point. Well out of harm's way, I alway's cringe when I hear my aerial catch on a bit of scrub. Top job mate.

Thanks good sir!

The side mounts always have bothered me for the trails we run around here. We lean/navigate close to trees. So many times has the rig come within an inch of something. This way I have zero worries about it. The antenna wasn't as much worry as the mount catching, and breaking what it was attached to.

 

[gmanpaint]

Had to replace another door hinge pin and also had to do the striker bolt. It still doesn't want to shut nice & tight tho. It's fully closed and it wont open on it's own or anything, but it's still loose a bit, enough to rattle some.

EDIT: I figured out how to adjust the striker bolt. It had to move inward about 1/4" and the door shuts tight and flawlessly now. Mo more rattles

 

[gmanpaint]

Ugh! EGR code showing.
Replaced both 02 sensores with Motorcraft dy733. Disconnected the battery for awhile, and took it for a test drive. 4 blocks later, and the CEL is back on.
Engine runs great, and cool. I don't feel anything wrong with it other than the CEL being on. Tags are due in a week, and it has to pass inspections. CEL on will fail the inspections.

I haven't checked the codes again, but will soon. So far I have done the following.

Cleaned the IAC
Replaced the DPFE with the new style and silicone vac tubes
Cleaned the MAF
Replaced air filter
Replaced EGR hard vac lines
Replaced both upstream 02 sensors

WTF else is there?

 

[cybergasm]

Register it in Kansas and not have worry about inspections

 

[gmanpaint]

After checking the codes once again.....

KOEO
332 & 335

KOER
117 & 337

3 EGR codes & 1 Temp sensor code. Frustrating.

Well the shackles have yet once again claimed another set of leaf springs. Pugly gets loaded down a lot with tools and heavy materials for work, and they have gone flat. The ride has gone to good to crap over bumps.

The leaf packs have been removed and are getting rebuilt today. Should be 2" over stock ride height and the war153 replaced with stock shackles. Had to take a cutting wheel to the drivers side front hanger bolt as it froze to the sleeve. New bushing and sleeve picked up at the dealer and being pressed in at the spring shop. Shopping for a set of tow helpers to help out.

It's always something!

 

[gmanpaint]

Picked up the new set of over the top helper springs to add to the leaf packs.

Was near the spring shop so I took a chance to see if just maybe he was finished. He only had one pack finished. Bet on black, but it came up red.

The new bushing I got from Ford was the wrong one.

Turns out I learned something new today. 91-93 use a different set of bushings than 94-01. 94 is when they went metric. Somehow, I have a 91-93 set on the 94

So, I hope the dealer will take the wrong ones back, as they weren't cheap for what they are. Plus the metal sleeve they sold me was the wrong one for the bushing. WTF!

 

[lynchy wa]

Horror run of luck there mate. Sucks that its happened in the middle of summer too. Hope Pug's is back, cooking with gas soon. Did you sort those codes she was throwing?

 

[gmanpaint]

Horror run of luck there mate. Sucks that its happened in the middle of summer too. Hope Pug's is back, cooking with gas soon. Did you sort those codes she was throwing?

Not yet Greg. I am going to remove and re-wire the new DPFE.
I might have crossed a wire or two, or maybe there is a bad connection from new harness to engine harness.

I just got back from the spring shop with the leaf packs. Going outside to slap it all back together.

 

[gmanpaint]

Leaf packs installed last night.

Enter the Snafu....

The stock shackles to replace the War153 extended shackles, I deemed not good enough for re-use.

Enter the Hero....

Turdle has a replacement set from an experiment gone wild and placed in the back of the "Experiment" shelf. Thanks Jon.

The war153 shackles are still on and the rear of Pugly and sitting with a 4" lift on stock shocks.

The over leaf helper springs are installed and look weird. Going to be some time before getting used to looking at them. The U-bolts are long, and point down. I cut the excess off with the cutting wheel. The replacement bolt/pins on the leafs had a round head that was too big to fit in the stock plates. So, out came the step bits and the holes enlarged.

Dealer did take back the wrong bushing and sleeve and gave a full refund

Pics after the new shackles are installed. It just looks way too funny to share right now...LOL!

 

[GRNMACHINE]

Come on Share, we are adults here! Well others are. Are those helper leaves from Hellwig? I had a set of those on my non awesome sport monoleafs many eons ago.

 

[gmanpaint]

Overleaf helpers are from Superior. There silver in color, and stick out like a sore thumb. Good thing I have lots of black paint