Project "Rubicon or Bust!"

[Cass007]

Jeep might be easier ... it just wouldn't start at all.

Hang in there Pete, you will get it dialed in. This is why I just replace everything once I start working on things. The cammo truck chirps once the belts get the slightest bit wet. I've just learned to turn up the radio, but I don't like how loud it is on trails.

 

[JeepinPete]

I usually just run things until the break. Then there is no question what is wrong

I forgot to mention, I'm still chasing oil leaks. Resealed the lower oil pan last weekend. Still have oil everywhere. So after the R&R on the idler pulley, I let it idle in the driveway for 10 minutes or so. The front crank seal that I replaced this spring...leaking like a sieve Which seal could I not get in a timely fashion back then? You guessed it, the crank seal. A Toyota seal has been ordered and will be installed in a couple weeks on my next vacation. Going to pull the front exhaust manifold while I am at it and R&R the oil cooler. Fingers cross that will be the end of the engine oil leaks.

 

[YotaFun]

Lo and behold, no noise. Both happy and a bit stumped. Like I said, this one doesn't play by the rules. So put the alternator belt back on, no sound. Reinstall the AC belt, and there is my noise. Spin both the idler and compressor sheaves, both feel alright, but one of them are making a noise. The idler went bad and was replaced on the '95, so I knew it was good, and easy to swap. Did that, and sure enough the bearing is toast.

Been there done that with my 4Runner and subsequently the reason I became a mechanic.
My first trip out to Paragon I went through some deep ice water after the engine had been running all day long and developed a load noise like you experienced.

I didn't know much about vehicles so I took it to a shop who said it was the A/C clutch, and $500 and a phone call, noise is still there, we think it might be a power steering pump.
Being poor kid working at a grocery store and pissed off that they didn't fix it after there sure fire diagnosis, I bring the truck home, get the cheapest power steering pump I can find (I think auto zone) grab my crappy beginners set craftsman tools and go to town.
After 5 hours of yelling and busted knuckles, I still had the noise. Now chucking tools across the drive way, someone on the forums suggest removing one belt at a time to pinpoint the noise. First was the PS, maybe a bad new pump? Nope noise still there... Next is the alternator, nope noise is still there, and Now I am furious because its down to the A/C belt, which once off, boom noise is gone, and I am still pissed because they just did the clutch, but then I grab the idler pulley and I can feel the looseness in the bearing -_-.

The idler sits dead bottom of the engine and I am sure super hot bearing in ice cold water was not the best mix for it. I was naive and stupid and should have made the shop that did it fix it, but I then would have never got the experience I did and end up doing what I am doing now. I also have about 3 extra of those idler pulleys sitting around for when it happens again! lol

 

[JZelnick]

posted in the wrong place, moving my comment to the trip Rubicon trip thread

 

[Cass007]

@JeepinPete ... let me know if you need the front main seal. Pretty sure I have a spare and I can mail it to you.

 

[surfishjoe]

Awhile back I had aengine whine it was the ac idler as well- sits way low on the engine like Avi says probably got toasted from water and mud.

 

[JeepinPete]

So the factory seal seems to have taken care of the majority of my oil leaks. The oil cooler assembly is weeping. I'll get to that sometime this fall.

Put on a new set of wheels and a set of 37" BFG AT's. Wish I had done that a long time ago. Much more civil than the KM2's.

Finally got to the steel yard two weekends back. Picked up a sheet of 3/16". Finally going to get to the rear bumper, as well as finish up the front.

Also picked up a new metal cutting circular saw. The cheapy I bought at tractor supply years ago let out copious amounts of smoke last time I used it. Don't think it was meant to cut 1/4" New saw is a Skilsaw 8" worm drive. Night and day difference. I've cut 500" of the 3/16" plate with the supplied blade, which now needs to be sharpened. It is much more controllable than the old saw for whatever reason, and far more powerful.

Anyway, worked on the pieces for the rear bumper the last few evenings. Got the inner frame plates cut and drilled:

Next up will be making up the bottom frame plates. Once they are ready, I'll weld the side and bottom plates together. Then it will be time to hack off the back of the frame...

 

[shmukster]

So the factory seal seems to have taken care of the majority of my oil leaks. The oil cooler assembly is weeping. I'll get to that sometime this fall.

Put on a new set of wheels and a set of 37" BFG AT's. Wish I had done that a long time ago. Much more civil than the KM2's.

Finally got to the steel yard two weekends back. Picked up a sheet of 3/16". Finally going to get to the rear bumper, as well as finish up the front.

Also picked up a new metal cutting circular saw. The cheapy I bought at tractor supply years ago let out copious amounts of smoke last time I used it. Don't think it was meant to cut 1/4" New saw is a Skilsaw 8" worm drive. Night and day difference. I've cut 500" of the 3/16" plate with the supplied blade, which now needs to be sharpened. It is much more controllable than the old saw for whatever reason, and far more powerful.

Anyway, worked on the pieces for the rear bumper the last few evenings. Got the inner frame plates cut and drilled:

Next up will be making up the bottom frame plates. Once they are ready, I'll weld the side and bottom plates together. Then it will be time to hack off the back of the frame...

Awesome stuff Pete, can't wait to see what the finished bumper looks like. And cutting steel with a circular saw is no easy task!!!!!

 

[jamarquardt22]

Awesome stuff Pete, can't wait to see what the finished bumper looks like. And cutting steel with a circular saw is no easy task!!!!!

Or quiet!

I wouldn't neglect the steering cooler. Mine was good and then it wasn't. Lost all fluid by the time I got home.

 

[JeepinPete]

These metal cutting circular saws cut steel like a normal saw cuts wood. But they do screech!

Steering oil cooler was changed out this spring. Already dealt with one popping, in the woods, on a trail, in NH. Didn't want to repeat that experience. The engine oil cooler is what I was referring to. It is weeping where it bolts to the block.

The following two pictures should be self explanatory:

 

[JeepinPete]

Make good progress this weekend:

Got the two caps on the wings to complete, then pull it off and weld it up. Lots of welding and flap wheel work left to do. Then get the air compressor fixed up so I can paint this, the steps, and the front bumper.

 

[shmukster]

Make good progress this weekend:

Got the two caps on the wings to complete, then pull it off and weld it up. Lots of welding and flap wheel work left to do. Then get the air compressor fixed up so I can paint this, the steps, and the front bumper.

I love it, go Pete!!!!!

 

[JeepinPete]

So I've been slowly picking away at this thing. Got the steps from the old truck stripped and spray bombed yesterday, and welded on today. Also finished up the rear bumper a couple weeks ago. I plan to remove the bumpers and step next spring to have them sand blasted and painted right, so the Rustoleum is simply to get me through the winter. Anyway, here are a couple pictures:

The rear bumper will eventually get a swing out for the spare. Also need to rework the exhaust pipe to bring it over the rear frame rail.

The front bumper will probably get the mounts reworked. A winch will be added one of these days. Also have to make up a couple more bars for the brush guard. Need to pick up a couple more weld ells to start that project.

 

[JeepinPete]

Well, it seems the direction of this truck is going to take a turn. I've been daily driving it since June of last year. Hasn't given me much grief. But I decided to pick up a newer vehicle for myself. Josh is turning 15 in a couple days, so I am 90% certain this is going to be his next year. Therefore, "Rubicon on Bust" = Bust

So the plan is to pull the lift springs out and put the stockers, or a set of OME that I have, in. My '95 had the body lift with no suspension lift, and it handled fine even with the oversized tires. Even with the mild lift, this one does not handle nearly as well.

 

[Pacer]

Well, it seems the direction of this truck is going to take a turn. I've been daily driving it since June of last year. Hasn't given me much grief. But I decided to pick up a newer vehicle for myself. Josh is turning 15 in a couple days, so I am 90% certain this is going to be his next year. Therefore, "Rubicon on Bust" = Bust

So the plan is to pull the lift springs out and put the stockers, or a set of OME that I have, in. My '95 had the body lift with no suspension lift, and it handled fine even with the oversized tires. Even with the mild lift, this one does not handle nearly as well.

Generally an 80 series handles just fine with a lift. Changing the rear track bar helps regain stock handling characteristics.

 

[JeepinPete]

So a long over due update. Not much has happened.

I hemmed and hawed all summer about what to do with the 80. In the end I am sticking with the plans in my last post. Picked up @BROKEROB1's 315's a few weeks back. Got them swapped on this week. Going through the brakes now. Replacing rotors and pads. Tore the rears down to get the parking brakes working again. Still need to go through the fronts.

Then going to pull the lift springs and reinstall the factory springs. Got to pull the winch too. I'm hoping Josh gets 5-6 years out it before the rust bug finishes it off.