In the process of chasing threads on all the standard bolts that were sent recently by a mechanic because I didn’t have the time. I keep repeating that behavior every five to seven years. One day I will learn.
Scope creep! What just happened? Tell me your story, dont act like it didn't happen...
- Thread starter tattoo80
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- Thread starter
- #22
great adventure. you set me at ease for the shenanigans over here seem minor now.
so my questions is.. did you realy just plan to fix the window or is that just the story you tell your wife and you quietly planned this major overhaul from the start.
great ride, btw. would love to see the end result. i'll look for a build thread or future posts.
haha yeah I had a feeling I would tear it all apart pretty soon. Build thread here: Builds - Ikarus' HDJ81 Aussie-Style Build - https://forum.ih8mud.com/threads/ikarus-hdj81-aussie-style-build.1306303/
- Thread starter
- #24
favorited and will be reviewing it. just the two first photos are beautiful. love that white one with two square headlights. i am considering using an older grill with the TOYOTA stamped on it for my 97. i think there is some trimming involved. then refresh the faded plastic lights with some glass one. i can't get the ones you had on that white one due to cost, but i would prefer them! thanks for sharing. will oogle it over later.
- Thread starter
- #25
you showed restraint, my friend. bravo!
- Thread starter
- #27
its always about the journey, and i get excited about tearing into new stuff and learning. today i pressure washed the tank and it's soaking in citric acid. totally salvageable. sorry you dont want to share a story. maybe you'll warm up later, and the term scope creep is not just limited to that field.
hisandhers80s
SILVER Star
In middle of scope creep hell as we speak! I bough a 4/1994 80 two to three months ago with 338,000 miles and to the previous owners best knowledge has never had the head gasket changed. I was going to do a solid base line on it and replace all the vacuum hoses, plug wires, oil cover seal, front main seal, thermostat, and change all fluids.
When taking the radiator out all the coolant hoses were crusty and rotting away, so I bought all new coolant hoses. Everything in the entire front of the truck is covered in oil and power steering fluid, so I decided to clean it all of really good to see what I was looking at. After taking the alternator out, I decided I needed new power steering lines. I had an issue with the power steering being weak, so decided to buy a new power steering pump while I was in there.
Next I disconnected the throttle cable because it was disintegrating and bought a new cable. Next I decided to remove the throttle body to clean it really good, and found that two of the hard vacuum lines were clogged. I bought an ultra sonic cleaner to get parts clean, and used it and mechanics wire and have not been able to unclog these lines. I found was able to source a throttle body from someone parting out an 80, along with all the head lights, tail lights, knock sensors, driver’s door, and dash HVAC unit.
After looking at the upper intake plenum and how gross it looked inside, I decided to take it off, which would also make it easier to replace vacuum hoses, and check the vacuum valves to make sure they were working properly. Then I decided once the upper intake was off to go ahead and take off the lower intake and get it cleaned up. Of course I dropped the lower intake just right and it broke the plug off the rear knock sensor. So I got two used knock sensors and replaced those. I also decided that since I was already hear I would change the pesky heater hose, and take the opportunity to get rid of the rear heater. I also decided to replace the ERG and the EGR modulator while I was here as well.
While testing the vacuum valves, I found that 3 of the 4 were not in spec, so I ordered 3 of them. Luckily the one that is NLA is still working for now. I also noticed that I had an oil leak around the distributor, so I ordered the o-ring, rotor button, and gasket for the distributor, and also decided I would put in new spark plug gaskets, so I ordered those and a new gasket for the valve cover.
Also, while unplugging the engine wiring harness from the knock sensors and fuel injectors, the plugs on the harness were crumbling. So of course I decided to pull the whole engine harness and restore it with new plugs, clean up any broken wires, and make sure the part of then harness that goes around the EGR was not melted.
Since I was doing all of this I went ahead and ordered the full suspension and sent my rear third member out for rebuild with 4.88 gears and an ARB Air Locker which is going to take 6-8 weeks to get back. Also ordered the front third member also with 4.88’s and an ARB Air Locker but don’t have to send this one out, they just send a new one. So then I decided I would go ahead and re-gear the transfer case with the sum or crawler gears and high range under drive gears. While inspecting under the truck, everything is still just coated in super thick layers of oil. So naturally, I have decided to go ahead and pull the transmission while pulling the transfer case to change the rear main seal. I also thought since I would have the transmission out and the suspension out as well, it would be smart to replace the upper and lower oil pan gaskets.
Last, I am going to do a compression test as soon as I get the wiring harness fixed up and back in the truck. The last thing I would hate to do would be this close to being able to get the head off to do a head gasket and timing chain and not do it while I am here. So, i will report back once I know if I am doing the head gasket and timing chain once I can complete the compression test.
I am also upgrading the brakes, axles, and birfields, along with front and rear bumper and sliders, but all of that was planned so not really a while you are in there addition.
When taking the radiator out all the coolant hoses were crusty and rotting away, so I bought all new coolant hoses. Everything in the entire front of the truck is covered in oil and power steering fluid, so I decided to clean it all of really good to see what I was looking at. After taking the alternator out, I decided I needed new power steering lines. I had an issue with the power steering being weak, so decided to buy a new power steering pump while I was in there.
Next I disconnected the throttle cable because it was disintegrating and bought a new cable. Next I decided to remove the throttle body to clean it really good, and found that two of the hard vacuum lines were clogged. I bought an ultra sonic cleaner to get parts clean, and used it and mechanics wire and have not been able to unclog these lines. I found was able to source a throttle body from someone parting out an 80, along with all the head lights, tail lights, knock sensors, driver’s door, and dash HVAC unit.
After looking at the upper intake plenum and how gross it looked inside, I decided to take it off, which would also make it easier to replace vacuum hoses, and check the vacuum valves to make sure they were working properly. Then I decided once the upper intake was off to go ahead and take off the lower intake and get it cleaned up. Of course I dropped the lower intake just right and it broke the plug off the rear knock sensor. So I got two used knock sensors and replaced those. I also decided that since I was already hear I would change the pesky heater hose, and take the opportunity to get rid of the rear heater. I also decided to replace the ERG and the EGR modulator while I was here as well.
While testing the vacuum valves, I found that 3 of the 4 were not in spec, so I ordered 3 of them. Luckily the one that is NLA is still working for now. I also noticed that I had an oil leak around the distributor, so I ordered the o-ring, rotor button, and gasket for the distributor, and also decided I would put in new spark plug gaskets, so I ordered those and a new gasket for the valve cover.
Also, while unplugging the engine wiring harness from the knock sensors and fuel injectors, the plugs on the harness were crumbling. So of course I decided to pull the whole engine harness and restore it with new plugs, clean up any broken wires, and make sure the part of then harness that goes around the EGR was not melted.
Since I was doing all of this I went ahead and ordered the full suspension and sent my rear third member out for rebuild with 4.88 gears and an ARB Air Locker which is going to take 6-8 weeks to get back. Also ordered the front third member also with 4.88’s and an ARB Air Locker but don’t have to send this one out, they just send a new one. So then I decided I would go ahead and re-gear the transfer case with the sum or crawler gears and high range under drive gears. While inspecting under the truck, everything is still just coated in super thick layers of oil. So naturally, I have decided to go ahead and pull the transmission while pulling the transfer case to change the rear main seal. I also thought since I would have the transmission out and the suspension out as well, it would be smart to replace the upper and lower oil pan gaskets.
Last, I am going to do a compression test as soon as I get the wiring harness fixed up and back in the truck. The last thing I would hate to do would be this close to being able to get the head off to do a head gasket and timing chain and not do it while I am here. So, i will report back once I know if I am doing the head gasket and timing chain once I can complete the compression test.
I am also upgrading the brakes, axles, and birfields, along with front and rear bumper and sliders, but all of that was planned so not really a while you are in there addition.
- Thread starter
- #29
thats what i did, but i stopped at the part where you rebuild the entire truck! lol.
i am impressed at the skill level here. I have a small drip on occasion and i think it's the rear seal, but i dont dare drop the transmission. looking for my ultrasound cleaner today so i can get these injectors back in. my gas tank is soaking with citric acid inside it now, and i am rotating it every so often. tomorrow my steeel brushes come in and hopefully one gasket that goes between the lower and upper intake.
since you are really into this project and probably changing the fuel filter, take a look at the gas tank via under the seat access panel. it wasn't too bad to remove, might need at least a new filter in there as well.
good luck ! thanks for sharing your adventure!
hisandhers80s
SILVER Star
I guess I left out the part where I am fabricating a panel for the passengers side rear to house the ARB compressor and other electronics. I am also going to buy a Bell Fab Tire carrier for the inside, and take out the 3rd row seats. But before I do that, I will remove the carpet and put down sound mat and address the fuel pump and filter when I do that. LOL
hisandhers80s
SILVER Star
I also bought new window runs for all the windows, and the window rocket to see if that makes a difference on the window rolling up faster.
- Thread starter
- #33
minor details, but of course this goes along with swapping out the radiator hoses. nice work!
EDIT: typo fix