New build thread from Arrowmntdiesel 87 4x4

[Halden]

Wow Mark. I remember when i did front end work on my truck it was a pain sitting on the cold garage floor... Thats a real nice set up!

[tdipup]

It's looking great! Maybe I'll come check it out over spring break!

[arrowmntdiesel]

Mark, some really interesting work! Quick question: Was removing the dashboard out of the truck a relatively easy process? It seems like you've done this multiple times - with multiple cracks in my own dashboard, it makes me wonder if trying to remove the dash to patch those cracks would simply make the situation worse.

Steve,

There are 10 fasteners too the dash component, some wires and ducting. It's not bad to remove and once out and on the bench, the dash pad itself will come off the hard plastic shell. The hardest bolts to remove may actually seem like the easiest. These would be the 4 phillips head, machine screws that are at both sides of the dash that are facing down towards the floor board. Why are these difficult you ask.....they thread up into a flat bracket that has a turned up edge on it that holds moisture and those little guys just don't want to break loose very easy at all. Use penetrating oil first and make sure you have the right sized screw driver. You're first attempt needs to be with a good grip on the bolt head and with a lot of upward pressure so that the screwdriver does not slip in the bolt head. There are screws behind the outer air vents as well and one under the steering column as well.

It's looking great! Maybe I'll come check it out over spring break!

Love to see you Chuck! I will continue to update on progress as it happens. Next I will tackle the rear axle and the back half of the chassis.

Thanks to all.
Mark

[Crabshackint]

Awesome job Mark, this is a great project. Thanks for posting updates.

[arrowmntdiesel]

Small change of direction here on the project. It was time to work up on the bench now. I have had a run of transmission replacements, the most recent from the local Oil Stop drive through. There guys installed gear lube in the transmission and it had begun to make noise. The owner of the truck directed them to me and I didn't have an overhauled transmission ready to go. Also the white truck I just hauled back from Wa. with Uncle Donnie needs a transmission, so ...... It's time to overhaul some trannys! I did the two 2wd already, these pictures are of the 5 speed 4wd on Chucks truck and the other MSG-5 4wd is for Tracy (Luvcamas).

Getting it disassembled I find a surprise... Notice the front countershaft gear

Here is a closer look at it

With the tooth being broken on the lower countershaft, that piece is a cast and machined component that includes all the other gears on the countershaft. It is not singularly replaceable. That means that if I don't have the exact matching countershaft to replace it with, then all the mates on the main shaft need to be replaced with it as well. (Which is what I ended up doing) Isuzu ended up using several different pitches and teeth count on the gears and the casting on the countershaft (rings) are an indicator of which gears they are.

I was keeping track of original paint daubs with my camera

Gears, bearings, seals and gaskets are all replaced and now the reassembly begins

Finally back together and right behind the assembled tranny is Tracy's tranny coming apart

The infamous bearing retainer plate that is diesel specific and the diesel bell. This Bell came from David Wallace that I picked up several years ago at the NW Pup meet in Rainer

Kept track of the paint markings just for the fun of it.

I'll keep moving ahead on it slowly and as always keep the board posted of progress. The Oil Stop truck comes in this week for a tranny swap.

Mark

[tdipup]

Most impressive, Mark! When this machine is finished, it may just take the Volkswagen's place in the garage! I'm essentially going to have a NEW little 4WD diesel truck! It's too bad some unfortunate circumstances kept me from making it over during spring break ... maybe I'll take a personal day in mid to late April.

[Beesboer]

Excellent job Mark! Why has the thread gone quiet?

[arrowmntdiesel]

Excellent job Mark! Why has the thread gone quiet?

I'm patiently waiting for "windows" part of Arrow-Mountain to give me a break so I can attend to the "Diesel" side of Arrow-Mountain.

It has been a very busy year for windows... but..I did just wash the frame off and get ready for finishing the chassis up after the 1st.

Stay tuned.

Mark

[Beesboer]

Looking forward! I'm busy with a project of my own, an '88 Pickup 4x4 C223. I envy you guys in the U.S. OEM parts seem quite easy to come by. I spent an hour with the parts guy at G.M. today for lower control arm bushes and fulcrum bolts, only to hear I may have them by next Tuesday...

[JoeIsuzu]

Mark, it was great talking with you Saturday. I'm just putting the forum on notice that I'm reserving a place in line for a project. I won't share any more details yet, other than that 1) it won't start until Chuck's truck is done, 2) Mark's family and glass business take priority, and 3) it involves the C223-T that's currently sitting in my garage--hopefully, with upgraded rods and a modern turbo.

Completion will no doubt be quite a while off--but I'm "officially" in the line!

Jack

[Halden]

modern turbo.

It would be interesting to pair a VGT with a C223... sadly you need some sensors and a control module for that. Be really great to have a VGT brake for it too!

[arrowmntdiesel]

Mark, it was great talking with you Saturday

Jack,
Likewise, It's always good to catch up with you and talk family. My how our kids grow up so quickly.

This truck project of Chucks is about to reappear hear in this build thread with the rear axle getting finished and the engine and transmission getting set in the frame. So stay tuned.

Mark

[arrowmntdiesel]

Update on this project:

Starting on the rear end section

All new rubber spring hanger bushings

New inner and outer seals and repack all bearings

New wheel cylinders, springs, linings, shocks

One side done

All lines ran now and new clips from Jerry

It is a bit difficult to figure out where I left off on keeping this tread updated. Sorry for any duplicate pictures. I looked back through the thread and tried to pick up where the last post was made.

Mark

[arrowmntdiesel]

Still moving on.....slowly,

fuel tank back in with new mounting pads

New U Joints

Front drive shaft

It turns out that both of these drive shafts were not the correct ones. I went through both of them that came off of this 87 truck, however, ( I should have known this from the previous conversion in 2012) the gas engines and the diesel engines sit in two different mounting positions in the frame, therefore the drive shafts between the diesel and gas engines are two different lengths. Rear drive shaft has a shorter front section and the front drive shaft is longer. The gas front drive shaft will bolt up fine, but the amount of spline engagement is decreased by 2" . not good!

Frame is getting very close now

getting ready for the tranny mount

New complete clutch

More too come....

Mark

[BravoDrew]

mind blowing!! looks amazing!!