Project "Oscar" 5spd D1

[ExpoScout]

I was wondering where you'd gone Jordan. Glad to see you back at it. I've also picked up a 5 speed, mines a 97. You coming to Uwharrie?

Perhaps. But at this point I'm really not sure. I need to make the switch to 235/85-16's ASAP. The 255/85's are way too big. I want to hang onto them for my scout, but I am afraid if I do that it will be awhile before I can afford some new tires. So at this point it's looking like I'll be selling these or finding someone willing to trade for what I want.

I'm kinda jumping back and forth between setting this one up and putting the 98 auto back to stock, so things have been a little slow. But I do have big plans for this one; the engine seems to be strong and the 5spd is awesome. There is VERY little if any rust on this thing. The only spots I have found are inside the boot that I'm gonna be taking care of and POR'ing. For now, however, I have lots of things to upgrade and get up to par on maintenance.

Also in the works is some rear storage, underseat vaults, the inverter, dual battery setup, additional map lights, and I'm probably going to build some sliders. That will be for starters and I'll see where it will go from there. I really just want it to be reliable and get me to some relaxing places, I'm not going to do anything that will jeopardize the reliability factor (one of the reasons for going to smaller tires).

 

[ExpoScout]

looking good... Off road, I prefer my 5 speed... traffic on I-4, give me an automatic.

love that green.

See ya on the trails one day...

I feel the same way. And the green is awesome! This and white are my two favorite LR colors by far.

 

[Wander]

If yours is like the 94 I had the rust in the back is probably from the rear door leaking. Will Tillery (roverguy) usually has DII door seals that are twice the thickness of the DI seals. I switched mine out and instantly noticed much less wind noise and better door sealing.

 

[ExpoScout]

You're probably right Matt...I was impressed at how little rust there is. One of the electrical grommets in the rear had come loose and the back end was filled with dusty dirt. You can definitely tell this thing came from out West.

How much do those seals run?

 

[ExpoScout]

So I guess it's time for a bit of an update:

I think I already mentioned that most of the engine is done. I replaced the valve cover gaskets, valley gasket, injector o-rings, plugs, wires, cap, rotor, hoses, serp belt, some misc bulbs, air filter, coolant, oil pressure sensor, fuel filter, and thermostat. Valve covers, intake, and all sensors I could get to were cleaned and checked. Radiator was flushed. Fuel pump was replaced just before I got it, so that is taken care of. When I finally started driving it the other day that alternator started squealing then dropped to only putting out 11 amps, so I replaced that also.

I went ahead and swapped the 255/85s out for 235/85s. Here's a pic of the new tires. MUCH better:

The difference is amazing and I should have done this back when the 255/85s were on the 98 auto. The 255/85s just put way too much strain on the drivetrain and without re-gearing were a pain in the *** to climb hills with at speed, without downshifting to a crawl.

I've got exhaust gaskets on the way. Although the exhaust gaskets that are on there aren't leaky, they are old and it's a matter of time, so I'll go ahead and swap them out of for peace of mind. I'm also waiting on magnetic drain plugs before I put in new diff fluid, trans case, and tranny fluid. I've also got a slightly leaky swivel ball on the driver's side and I will be going through and re-doing the seals there as well along with new gear oil in the housings. Flushing the brake system and clutch master cyl is on the list of to-do's as well.

I had a weird thing happen yesterday too. I pulled out of my driveway to go to the tire shop and my temp gauge shot up. I turned right around and coasted into my driveway to trouble-shoot the problem. I got on the phone with PT Schram (who by the way I must thank for his willingness to put up with my endless barrage of questions and brain-picking) and after going through everything I ended up pulling off the temp sensor wire and tightening the connection. Evidently it was just an electrical issue. I went to the tire shop after that and all was well.

I already have some proper autometer gauges that will be going in just as soon as I figure out where I'm mounting them. I hate unreliable and inaccurate stock gauges.

Well that's it for now. Might have some more updates after this weekend. I'll see how much time I have.

 

[ExpoScout]

Drove almost 125 miles since the temp gauge issue and everything is good. Guess it was just the connection after all.

I fixed the passenger rear window issue. The plastic roller had broken into two pieces. I replaced it with a metal roller so it should be good for the foreseeable future. I actually used a quarter which was the perfect size. I'm contemplating preemptively doing this to the other three windows as well.

Also picked up a bunch of oil, fluid, etc today to go replace everything in the next little bit. I'll probably do the tranny and trans case tomorrow. Once the magnetic drain plugs come in for the diffs I will change the diff fluid as well. The list is getting shorter of things to fix/replace. After doing all fluids the next thing will be the front axle seals/bearings/etc.

I need (ok, want) a ladder for the rear and I'm looking into roof racks. Rear storage is definitely on the list of things to work on. I have the plans for it in my head, we'll see how they pan out.

 

[ExpoScout]

Got the transfer case, transmission, and engine oil replaced. Also re-gasketed (is that a word) the transfer case cover and oil pan. Most of the fluids were pretty nasty, but everything I could see inside looked good. I used cheap lubricants this time because I want to flush any crap out of the cases and I will change them over to higher quality lubricants in about 500 miles.

Other things to work on include installing proper gauges, fixing the passenger front door handle that won't open from the outside, still have to change the diff fluid once the magnetic plugs come in, go through the brake system, flush the brake/clutch fluid, and then it will be onto the fun stuff...

 

[LtFuzz]

Looks great.

The 235s look WAY better. I also like that you went with the white facing out -- I've always been a fan of that. Don't know why most people turn the white in.

 

[ExpoScout]

Looks great.

The 235s look WAY better. I also like that you went with the white facing out -- I've always been a fan of that. Don't know why most people turn the white in.

I couldn't remember the last time I put the white out, so I decided to switch it up a little.

 

[ExpoScout]

In addition to doing little maintenance things (fixing sticky door handles, etc) I also made a locking plate for the spare. It is easily removable and the lock and plate can be taken off before going on a trail where spare use might be imminent:

I even added some left over reflective tape (for safety's sake of course )

 

[LtFuzz]

Hmm, you sure you're not gonna get driven up the wall hearing that lock clank away as you go down the road?

 

[ExpoScout]

Hmm, you sure you're not gonna get driven up the wall hearing that lock clank away as you go down the road?

Nope, it rests on a rubber cap that slides onto the bottom lug :ylsmoke:

 

[LtFuzz]

Nope, it rests on a rubber cap that slides onto the bottom lug :ylsmoke:

Haha, well played sir!

 

[ExpoScout]

Haha, well played sir!

I just happened to have one lying around that was the perfect size. After I got it installed I noticed that I would probably get annoyed by the noise and found the cap. Works nicely so far.

 

[ExpoScout]

So over the past several days I noticed that after driving around and getting up to temp, if I sat in a drive-thru or stationary with the rover running for any length of time, the temp would start to creep up. Checked my fan clutch and decided this was most likely the culprit (in addition to a radiator that although it has been flushed, probably has seen better days).

I really didn't want to spend $100+ on an OEM clutch, so I did some research and found that lots of people have successfully used a Chevy clutch in lieu of the LR part. If you need to search for it just put in 96 Chevy 1500 with 4.3L and it will come up. If you go to autozone there are two part numbers: 215157 is the heavy duty and 215158 is the severe duty. After looking at the "severe duty" clutch I determined it is way overkill unless you do a ton of wheeling in very hot places, then it might benefit you. The 215157 (actually Autozone Part # 922626) is definitely a step up from the stock clutch (or at least my old decrepit one). If you get it from autozone it comes with new bolts. It was $47.99 and fits great. The only modification you have to do is take a stepped drill bit and take the holes on your fan to 3/8". A regular drill bit will work, but the stepped drill bit stays centered better and will not "egg" out your holes. Put it back together and it's done.

I haven't driven around yet with it to determine if it has helped the temp spikes I was getting while sitting still, but I can tell that it is moving a lot more air. So I will go ahead and call it a success thus far. AAR to follow.