Rusty, crushy, but trysty.

[makman1297]

Cleaned up the rest of the old rear suspension. Was able to put my angle iron brace in the inner frame lower rail with some bolts and some welding should be better than new. Used a lower brace off the suburban frame to replace the rotted one on the truck. I got the 4wd leaf brackets installed. The front ones the 4 one the bottom frame rail were the same but the 4 one the side were not the same, the 4wd bracket is about 1/2 wider so the holes are slightly wider. This required welding the old holes shut and then re-drilling them out, yeah. The rear brackets were the opposite, the side ones were the same, but the bottom two were off by about 1/2 an inch. I got one set of leafs apart and put the new bushings in them, and put it back on the truck, just need to stop and get some new shackle bolts. I started cleaning up the 14 bolt, i am grinding the perch's and some square thing off, guess must of been for the bump stop.

[makman1297]

Got the rear springs installed, and the perch's removed. Ready to weld the new perch's on the axle.

[makman1297]

Started with the rear axle, tack welded and then tore the gears out to put the 4.10 gears in it.

[gshibler]

Do you go low budget on the gears too? Junkyard or new. The old truck will be up and running in no time.

[makman1297]

Wow spent the day just working on the rear axle, what a pain. I got the gear set used off ebay, and found an install kit, but it took a good part of the day to get them set up. I ended up getting a new impact since mine crapped out. Got the rear end in the frame and the diff done. I got the shock brackets off and still need to weld them in the correct spot. I also need to make the bracket for the rear brake line.

[makman1297]

Only worked on it for a few hours but felt like i got alot done. I welded on the shock brackets, installed my second fuel tank, drilled and mounted the front axle bumper, cleaned and painted the frame, and installed a new style spare tire carrier. I also started tearing the tranny apart.

[gshibler]

Very Nice! Looking good. Hows tranny so far. Is that the one out of the 88 or the donor burb.

[makman1297]

Its the one from the 88, but the code on it says 87, so far its ok, have not gone very far yet.

[gshibler]

It should be in decent condition. It was rebuilt like three times by Aamco under warranty when I had it, and Dad didnt put that many miles on it. They said it got a new valve body at one point or another. The only funny thing it did and they never were able to fix it was it shifted kind of hard from 1st to 2nd. Looks like the 14 bolt cleaned up and fit nice.

[makman1297]

May of had a sticky valve, i have all the good tranny parts for it. The axle was a little rusty but should be good. It gave me a bit of trouble with the gear setup but i think its good. Brakes look decent on it and i put in new axle seals. Just half to run the brake lines. My bushings are due in thursday, so that means i can clean up the front springs and put them in. Then i can get the engine, tranny, and transfer case in.

[makman1297]

oh boy the spring bushings came in.

[makman1297]

Spent most of the morning cleaning up the front springs and putting the new bushings in. Got that done found the dr caliper is bad and the ball joints on the pass is bad. Got the front axle mounted in again. I tore the rest of the tranny apart and pulled out all the parts, just started putting it back together, maybe tomorrow i can finish it.

[makman1297]

Spent the day working on the tranny, got the internals done. Just have the valve body left to finish up.

[makman1297]

Almost done with the tranny, valve body in.

[makman1297]

Installed the motor and tranny in the frame today, the motor mounts didnt line up the greatest, but after an hour of torture it gave in. Hopefully will get the t-case in tomorrow.

[makman1297]

A little progress, got the starter in, t-case, t-case crossmember, put in new u-joints. I think i will be able to use the original drive shaft, will soo how it looks with all the weight on it. I pulled the case apart on the t-case and resealed it, it looked very clean on the inside.

[makman1297]

Today i got the axle perches fully welded, rear brake lines in, front brake lines, started with routing the fuel lines. Also started pulling the front axle apart to re-gear it.

[Factor]

i got a 86 4x4 and mine was just as bad (being in canada where the salt is so bad the roads are white from the salt in winter), the process is just minotnous, i stripped mine to a bare fame and cab even the fire wall was shot and sponge dame near every panel ,mount, rocker etc was replaced it takes time and somtimes is fustrating ,urs is looking great as the other guys said. i like the diy's that acctually do it with 95% steel instead of just getting a body shop to bondo it and cover it for them

[owner 84]

It looks awesome

Keep updating bro

[owner 84]

Did you installed two fuel filters?

[makman1297]

Thanks factor, it does take forever. Owner 84 its a fuel filter then a electric fuel pump for the TBI. I have some more finessing to do with the fuel lines. Ordered some more parts today, hopefully will have the running gear done by next weekend.

[makman1297]

Finished up routing all the fuel lines, it took alot longer than i thought. Also got the tv cable hooked up and adjusted. Installed the trans temp sender in the pan.

[Zebb]

It's coming along great makman1297!
I got a question about sealing up your 208. In my build I used a different 208 and installed it without fluid in my chassis. I didn't fill it until after I had the body on it. Now that I have filled it with fluid I have a leak at the case halves. What do you think of splitting the case in the truck with the cab on it? Would you do it or would you pull it and split it on a bench? I wish I would have known about it when I was at the same point as your build.

Thanks for your opinion on this.
Zebb

[makman1297]

Hey zebb, it seamed pretty easy to do, just remove the bolts from the rear section, mine had 4. Tap it with a rubber hammer and slide it off, mine had a plastic shield in that section that pulls off. Next remove the case bolts i think 14 of them that are 14mm. Tap that section and pull it off. There is a shift lever with a spring and washer that will fall out, and the magnet may fall out. Thats about it, i think it would be pretty easy even with the cab on. I found on mine for re-installing it that the shaft pulls out a ways and you can slide the spring and washer on without having to compress the spring, makes it much easier for re-assembly.

[owner 84]

looks awesome

Where did you get your fuel selector from that has all hoses connected with? Is it OEM? How much?