"Dirt Digger" Project

[helo-mech]

A quick history. After having a couple of 4th Gens and to fulfill my desire to have a hobby/project/camping vehicle for the boys, I picked up this 1st Gen 3.0 5-speed for $600. I asked my 7 year old what he wanted to name it and he spit out "Dirt Digger."

I knew going in that the wheel bearings in the driver front were shot and figured I might as well go ahead and convert to manual hubs. Ordered the hubs from Warn, picked up all the bearings and pulled it into the garage.

You can see in the picture that the driver side looked like it exploded. The races in the driver side were a PITA. When they let loose the PO drove it to the point where the center cap on the wheel melted. I guess all the heat really locked them in there well.

Once off I noticed some pitting in the driver hub on the outer race housing (right side of 3rd picture). I don't think this will be that big of a deal but if anyone has any other ideas, please don't hesitate to let me know.

As it sits right now, it will be a couple of days before I can get back out there. Work is gonna get in the way for the next 3 days.

 

[Hyde802]

Looks like a good start! Good luck on those wheel bearings!

 

[BucknutBob]

For $600, you did very well! That body looks like a $2500 rig, plus a nice aftermarket rear bumper to boot. Best of luck!

 

[helo-mech]

Well the rebuild is on hold for a little while now. Once cleaned I noticed the driver side hub is scarred and grooved pretty bad. On the hut for a hub now.

 

[helo-mech]

Found a hub yesterday in a local yard for $45. Installed all the races/bearings and manual hub conversion kit today. Nice that I can actually drive it now, but I may have torqued the right side axle nut a little too tight. I have a high pitched whine coming from the right side when moving.

Be a couple of days till I can look. Why does work always get in the way?

 

[helo-mech]

Haven't posted any updates in a while, so here is where I am right now.

Had some time today, no money just time, so I took off the sway bar, mud flaps and the fender trim. Also figured out the whine I was hearing. Looks like it is coming from the u-joints. I put it on jack stands and ran it up to 30mph to isolate the noise. Once I got under there I noticed the FWD zerk fitting had come out. I'm sure all the grease followed. Hoping to change those out this week sometime.

Started a little sanding to see what my options are with the rust and I think I have decided to clean it all up, fiberglass and body fill to keep it stock looking. I don't think I will ever go to anything over 33s and from what I am reading they would fit with the stock fenders and a little trimming.
P1020507 | Flickr - Photo Sharing!


Turned the torsion bars down 2 turns, but with size of the threads I don't think it did a lot. I'm gonna turn a little more to see if I can't get the front down a little. PO had them cranked up all the way.

Truck came without the pass window switch and a supposedly bad pass window motor. Did some trouble shooting with some jumpers and I do think the motor is bad. Nix99 is sending me the switch. Took the motor out, what a PITA, and I'm now waiting for the switch. I will be ticked at myself if the motor aint bad and I pulled it for nothing. But I was bored, and kept going hoping I am right.

 

[helo-mech]

I hate backwards troubleshooting!!!!!!!!!

I got everything I thought I needed to get this passenger window going. Got it mated up in the door, did some quick temp wiring and nothing. Jumped the motor from the battery and it worked like a champ. Started taking some voltage readings and found that I only had 4.5 volts at the motor when the switch was activated. Check the power to the switch and had 12 volts.

So I went looking for the "Door Control" relay box. Found it behind the ECU, right where it should be, and of course once I had it out I could smell the burning smell. It didn't look bad but I am gonna assume with the smell that it is in fact bad.

So now I'm trying to decide which way to go. Part of me is thinking that I should just wire 3, 3 pole switches in the center console for the 3 windows and call it good. The other option would be of course to find a control box.

 

[helo-mech]

On a good note. I got some shoulder seat belts in the rear installed. Now I can take the kids around.

 

[SV_Dude]

I would get rid of the power windows and find some guts from a manual window door and install them. In my mind, less is better. Keep things simple to keep reliability up. If you don't want to do that then I would go with your idea and wire your own window switches.

 

[TN_GIJOE]

that thing looks really good for $600.:trophy:

 

[BucknutBob]

Warning: off topic note--Hey GIJOE, I just noticed your sig. Geez, you're as bad as me, with all those 2nd Gen's. I'm on my third, too. I'll always like their styling best--if only they came with a better engine (LOL)!

 

[helo-mech]

Warning: off topic note--Hey GIJOE, I just noticed your sig. Geez, you're as bad as me, with all those 2nd Gen's. I'm on my third, too. I'll always like their styling best--if only they came with a better engine (LOL)!

Hey now you can't go off topic and then dog the 3.Slow. Espically when I have the same problem, I mean engine. :lmao:

Wanna go off topic? I have a friend who is trying to talk me into dropping an LS in mine.

 

[helo-mech]

that thing looks really good for $600.:trophy:

Thanks man. Hoping to help it a little with some rust repair/fender mods.

 

[helo-mech]

I would get rid of the power windows and find some guts from a manual window door and install them. In my mind, less is better. Keep things simple to keep reliability up. If you don't want to do that then I would go with your idea and wire your own window switches.

For some reason even with the number of yards in the Houston area, I haven't had any luck finding any 1 Gens around for parts. I might start piecing things together over time for some manual windows cause I do like the idea of keeping it simple.

Good news is I gave the control box a little electrical component "drop kick" and everything is now working. I doubt it will last long so I'm gonna go ahead and get the relays and what not ready to make my own switch panel in the center console. SV I think it was you that posted a schematic of a back window setup. I copied the picture for my notes a while back and I plan on just adding to that set-up for all three windows.

 

[eggbeater]

Nice find! I hear you on the part scarcity here in Houston...someone told me that there is a local ordinance requiring the destruction of any vehicle older than 20 (I think) years old...stinks.

And you have friends like mine...one just dropped a V8 in a miata. If you need any help wrenching let me know...I work right next door to you guys!

 

[helo-mech]

Nice find! I hear you on the part scarcity here in Houston...someone told me that there is a local ordinance requiring the destruction of any vehicle older than 20 (I think) years old...stinks.

And you have friends like mine...one just dropped a V8 in a miata. If you need any help wrenching let me know...I work right next door to you guys!

That would make parts hard to find for sure. I'll have to catch up with you. I figured you must be next door from your pic. I'll PM you my contact info. Have to grab a beer and check out the rides.

 

[helo-mech]

Put some hooks in the garage ceiling and attempted to take the top off today by myself. Can't take credit for it as I saw someone on here that said to just use friction straps. Once I had all the bolts disconnected, I slid it back a little ran a strap along the back, hooked up the front, lifted them all a little and drove out.

Worked like a champ. I was even able to put the 4Runner back into the garage, nose in or back in. Best part of all though was I was able to put the wife's car back in. This of course was a MUST.

Next is the U Joints and some MDF boxes for the inertia reels that I added for the rear seats. Got to keep the dust and dirt out of em.

 

[helo-mech]

I am by no means a carpenter, I can't draw a straight line with a ruler, but I finished my box behind the seat today. I'm not real happy with the way the gasket material for the inertia reel came out but I have an idea that I think I will like. It's not meant to be water tight or any thing, just looking to try and keep some of the dust out of the mechanism. Once I take it all out again for the POR-15 that I plan on doing, I will fix it.

Also redid the hooks in the garage. Now I can back or pull straight in with the 4Runner and the wife's car.

 

[helo-mech]

Have had more time than money lately so not a lot has changed. Today I took the step bars and rear bumper off to get ready for some sanding and rust repair. In doing that VenomHP suggested we steal the 33's off his 4th Gen to do a quick test fit/test drive. Thought was we could get an idea of what, if any, needed to be trimmed during the repair process.

The ride with the 33's was great. It was a little sluggish in 1st and 2nd but overall I was really happy with it. Made my decision for 31s or 33s real simple.

Should have my sliders ordered this week and maybe some new leafs.

 

[helo-mech]

Few pics from a couple of weekends ago. Went and volunteered at a Wheeler's for the Wounded event. Great experience! Spent the day before the event marking trails and setting up. Did shuttle rides during the event since I didn't quit trust "Dirt Digger" yet.

My camera dropped out of the truck first day out and smashed a rock so all I have are these two crappy cell phone pics. Still waiting for pics from others. From what I hear there are some much better ones, but not much you can do when you are waiting on someone else I guess.