Frame Rot!! Is this the end?
- Thread starter TheDurk
- Start date
LittleCaesar
New member
Very impressive. I would have gotten another 3rd gen and called it a day.
I love the ingenuity with the logs and other non normal frame off body proclivities though the rake in one of the pics is baffling in its use here.....
I love the ingenuity with the logs and other non normal frame off body proclivities though the rake in one of the pics is baffling in its use here.....
TheDurk
Elite Member
A retrieval tool possibly?
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Exactly. I hate bending over and little parts and tools always end up under the center of the truck. The rake gets them out. I also have a telescoping magnet wand for real small stuff.
Weather report says I'm shutting down the rest of this week, and I'm going away this weekend. I hope to have this truck back on the road next weekend.
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TheDurk
Elite Member
If you've owned a truck for 17 years, it's hard to go buy one that some idiot has maintained and deal with nasty surprises. I fought hard to get an IJM 5-speed 17 years ago and I won't settle for anything else. (I wish I had known what a locker was, or I would have gotten that.) This truck has been stone-cold reliable since new, and I think it deserved this effort after all we have been through together,
I feel the same way about mine, she has been solid as a rock.
TheDurk
Elite Member
Update:
Several days of rain, then I was away for the weekend. Back at it now, until Hurricane Matthew gets here. Sigh...
Big day today, although not very photogenic. First had to get the exhaust to line up, before raising the frame. It was too far back:
So I had to put a luggage strap on it and that did the trick:
Then I was able to go ahead and raise the frame into place. Had to go very slowly and keep checking all the body mount bolts were not getting hung up on the side of their holes. Tightened up the exhaust at the end. The air jack was great for this. Then I swapped the jack stands from the body to the frame, which was a big moment, but doesn't make much of a picture. Now I've got 4 6-ton jacks on the frame at each wheel well, two 4-tons in back on the hitch, two 3-tons in front on the frame cross member, the crane on the engine, and the rolling jack on the back of the trans, plus a few logs for fun. Now I can get under with composure to finish the job. I always felt a bit queasy when it was just the body being supported and I did almost everything from the sides.
The engine is fighting me. It doesn't want to sit perfectly on the body mounts so that I can get those bolts in. I've never done an engine swap so I guess I have to review a few of those threads. I suspect this is never easy. I'd really like the dang crane out of the way. Hopefully tomorrow.
Several days of rain, then I was away for the weekend. Back at it now, until Hurricane Matthew gets here. Sigh...
Big day today, although not very photogenic. First had to get the exhaust to line up, before raising the frame. It was too far back:
So I had to put a luggage strap on it and that did the trick:
Then I was able to go ahead and raise the frame into place. Had to go very slowly and keep checking all the body mount bolts were not getting hung up on the side of their holes. Tightened up the exhaust at the end. The air jack was great for this. Then I swapped the jack stands from the body to the frame, which was a big moment, but doesn't make much of a picture. Now I've got 4 6-ton jacks on the frame at each wheel well, two 4-tons in back on the hitch, two 3-tons in front on the frame cross member, the crane on the engine, and the rolling jack on the back of the trans, plus a few logs for fun. Now I can get under with composure to finish the job. I always felt a bit queasy when it was just the body being supported and I did almost everything from the sides.
The engine is fighting me. It doesn't want to sit perfectly on the body mounts so that I can get those bolts in. I've never done an engine swap so I guess I have to review a few of those threads. I suspect this is never easy. I'd really like the dang crane out of the way. Hopefully tomorrow.
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RunnerRnd2
New member
This is impressive, I was proud of myself for removing my bumpers and running boards today...
TheDurk
Elite Member
Update:
I haven't posted in a while. I got the engine in--I just had to shift the crane a little bit and set her down in the right spot. Putting the trans mount bolts in first seemed to make it it all easier.
The other big fight was the panhard bar. It was as if it was about 3/8" too short. I had to rig a come-along between a crowbar against the bumpstop and panhard mount on the passenger side and a chain around the lca mount on the driver's side. That got it done.
Then it's just been slow, steady progress rebuilding the entire chassis. Two or three hours a day is the what I've been doing, about four days a week. There is just an awful lot to do. Today was a big day. I finally got the knuckles in, so that allowed me to put in new coolant and PS fluid--and gasoline--and start the engine for the first time since July. [Why did I need the knuckles in to start the engine, you may ask? The knuckles carry the ABS sensors, and I did not want to fire up the ignition without those connected for fear of setting a code that I would need the dealer to clear. I have my bootleg TIS computer, but I'm not confident enough to risk a diagnostic fee on it.]
She coughed on the first key turn after about eight seconds of cranking. Then she started right up on the second turn of the key. Made a few scratchy sounds for about a few seconds and then settled into the smooth running V6 she has always been. I love this truck. No lights, no codes and no leaks. YES!
I put EXACTLY five gallons into a bone-dry tank. This what the gauge looks like with five gallons in it:
When I get her rolling, I'm going straight to the station and fill her up with my shortened fuel tank vent pipe and see exactly how much gas fits in this thing. Then on to the alignment shop.
Should happen Wednesday or Thursday.
I just have to:
-do driveway alignment well enough to get to the shop
-install steering rag joint, once I am sure where straight ahead is.
-hook up e-brake and finish right rear drum brake
-fill with brake fluid and bleed
-fill both diffs
-install both driveshafts
-install both swaybars
-put the wheels on
-torque a few bolts once the suspension is loaded
and pray everything works. Oh yeah...and pressure wash all the anti-seize off my beautiful black chassis and everything else. It's everywhere.
Here is a shot of my driveway alignment tool (right side):
Today's insight:
If you ever have to rebuild a front end, there are some non-intuitive rules to follow, all of which I broke, to my regret.
1. Do not put the front diff on until you have inserted the long horizontal bolt for the steering rack. You will have to unbolt the diff to get it in.
2. Put the lower control arms on before you mount the rack; otherwise the rear cam bolts won't go in. You will have to unbolt the rack to get them in.
3. Do not put the shocks in before tightening the UBJ and LBJs castle nut to the UCA and LCA. Otherwise when you try and get the UBJ into the UCA, you can't. Putting a jack under the UCA just lifts the whole truck without getting the UBJ stud into the UCA. You will have to unbolt the shock to get the stud threaded up.
Hope these help someone.
I haven't posted in a while. I got the engine in--I just had to shift the crane a little bit and set her down in the right spot. Putting the trans mount bolts in first seemed to make it it all easier.
The other big fight was the panhard bar. It was as if it was about 3/8" too short. I had to rig a come-along between a crowbar against the bumpstop and panhard mount on the passenger side and a chain around the lca mount on the driver's side. That got it done.
Then it's just been slow, steady progress rebuilding the entire chassis. Two or three hours a day is the what I've been doing, about four days a week. There is just an awful lot to do. Today was a big day. I finally got the knuckles in, so that allowed me to put in new coolant and PS fluid--and gasoline--and start the engine for the first time since July. [Why did I need the knuckles in to start the engine, you may ask? The knuckles carry the ABS sensors, and I did not want to fire up the ignition without those connected for fear of setting a code that I would need the dealer to clear. I have my bootleg TIS computer, but I'm not confident enough to risk a diagnostic fee on it.]
She coughed on the first key turn after about eight seconds of cranking. Then she started right up on the second turn of the key. Made a few scratchy sounds for about a few seconds and then settled into the smooth running V6 she has always been. I love this truck. No lights, no codes and no leaks. YES!
I put EXACTLY five gallons into a bone-dry tank. This what the gauge looks like with five gallons in it:
When I get her rolling, I'm going straight to the station and fill her up with my shortened fuel tank vent pipe and see exactly how much gas fits in this thing. Then on to the alignment shop.
Should happen Wednesday or Thursday.
I just have to:
-do driveway alignment well enough to get to the shop
-install steering rag joint, once I am sure where straight ahead is.
-hook up e-brake and finish right rear drum brake
-fill with brake fluid and bleed
-fill both diffs
-install both driveshafts
-install both swaybars
-put the wheels on
-torque a few bolts once the suspension is loaded
and pray everything works. Oh yeah...and pressure wash all the anti-seize off my beautiful black chassis and everything else. It's everywhere.
Here is a shot of my driveway alignment tool (right side):
Today's insight:
If you ever have to rebuild a front end, there are some non-intuitive rules to follow, all of which I broke, to my regret.
1. Do not put the front diff on until you have inserted the long horizontal bolt for the steering rack. You will have to unbolt the diff to get it in.
2. Put the lower control arms on before you mount the rack; otherwise the rear cam bolts won't go in. You will have to unbolt the rack to get them in.
3. Do not put the shocks in before tightening the UBJ and LBJs castle nut to the UCA and LCA. Otherwise when you try and get the UBJ into the UCA, you can't. Putting a jack under the UCA just lifts the whole truck without getting the UBJ stud into the UCA. You will have to unbolt the shock to get the stud threaded up.
Hope these help someone.
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TheDurk
Elite Member
Just got back from a TEST DRIVE!!! She rides again. My gut feel alignment was amazingly good--cant wait to see the sheet at the shop to see how close. But it didn't pull at all or feel anything but normal. 'Truth is, I noticed that all the cam bolts on both the old frame and new frame were set at 12 o'clock exactly, so I did the same. And the TRE's are as close to 1mm toe-in as I could get with a tape measure and two yardsticks clamped to the rotors. I think it's a little more than that, but it won't shred my tires in the four miles to the shop. The rag joint I set to my paintmarks I did when I took the frame off, and the wheel still tracks straight.
Tomorrow I will put the front driveshaft, swaybar and bumper on, and give it a good pressure washing. There are anti-seize fingerprints and smears everywhere. Then I'll take some nice pics on the lift at the alignment shop which is booked for Thursday.
Now I get to add up all the bills and see what this adventure cost me. Pretty sure it's less than welding up the old one, and now everything underneath is solid, POR15'd, anti-seized, and torqued to spec. Glad it's over but I'm glad I did it.
I did set an ABS light, and I think it's because one of the rear sensors didn't go in all the way. Probably some POR15 in the hole. So I get to try out my pirate Techstream rig that has been sitting around waiting for a moment like this.
Tomorrow I will put the front driveshaft, swaybar and bumper on, and give it a good pressure washing. There are anti-seize fingerprints and smears everywhere. Then I'll take some nice pics on the lift at the alignment shop which is booked for Thursday.
Now I get to add up all the bills and see what this adventure cost me. Pretty sure it's less than welding up the old one, and now everything underneath is solid, POR15'd, anti-seized, and torqued to spec. Glad it's over but I'm glad I did it.
I did set an ABS light, and I think it's because one of the rear sensors didn't go in all the way. Probably some POR15 in the hole. So I get to try out my pirate Techstream rig that has been sitting around waiting for a moment like this.
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ZionXIX
New member
Awesome job man! That was a beast of a project. You deserve every bit of that victory lap to alignment shop. [emoji41]
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shahsmerdis
New member
am i the only one that every time i read 'is this the end' the sky fall song plays in my head?
.
.
. moving on...
Great job!
.
.
. moving on...
Great job!
TheDurk
Elite Member
So, first report on fuel pipe circumcision experiment. After adding exactly one full five-gallon tank to a bone dry truck, I drove about six miles in test driving and then filled her up on my way to the alignment shop. I got 14.1 gallons in, with the needle at a point where I would have gotten 12 or less before. It means I got the full 18.5 gallons in, allowing for test drive and filling all the fuel lines, rail, filter, etc.
Looking forward to see what happens at the first true fill-up, but it looks like a success.
Report on the alignment tomorrow night. I won't relax on this job until I see a clean green alignment sheet.
TheDurk
Elite Member
And now it is officially done. Clean alignment and truck is running great. A few weird settling in noises which I assume is the body accommodating to a new chassis. I'm actually quite impressed by my totally eyeball driveway alignment. I had caster and camber in spec, and wasn't that far out on toe -in. I could have done better, but I figured I'm paying these guys, right? I just wanted not to shred my tires getting there.
Thanks to all of you who provided moral support through a long and fairly arduous adventure far beyond anything I have done before. This forum and all of you are great.
Thanks to all of you who provided moral support through a long and fairly arduous adventure far beyond anything I have done before. This forum and all of you are great.
fightman80
New member
Well done Sir! I've been busy with work happenings.... but my God!! You've done it man! Congrats!
layball:
Rock_Rat
Senior Member
It's been a real pleasure following your intense undertaking. As an original owner, I truly understand your desire to put everything you have into your rig and breathe new life into it the way you have. I have a tremendous amount of respect for you. Pretty amazing accomplishment. This one's for you! :cheers:
shahsmerdis
New member
what did the tech say when he knew what you did? 
