Hockeydad4-22

[Justin]

How old are the lines/pump/tank/etc.?

[Viperwolf1]

Trace out the fuel lines and make sure you have pressure line at the correct end of the rail. Regulator dumps fuel to the return line so the end connected to the reg is return.

[hockeydad4-22]

Justin - lines range from the original 1995 lines to brand new but all were clear, I blew them all out before I installed them. Pump is the factory 1995 pump retrofitted into a 23 gal tank (amazing how well that worked out for us)

Viper - that makes sense - you can bet I do that before I head into the house tonight after work! Whew, wouldn't that be nice! I am crossing my fingers (and uncrossing my lines I hope)

[landshark]

I hooked up my Efi lines backwards as well. Easy fix :)

[hockeydad4-22]

It's alive. Crossed fuel lines, turned the key and fuel pressure read 34 psi. Cranked for about 3 seconds and she roared to life. Pressure held steady at idle at 45 psi and up to mid 50s revved up.


After that I got startled tidying up all the wires. I won't get to work on her tomorrow or Saturday and Sunday Kirk and I are going on a road trip so come Monday I am going to get a bunch done daily until Drew can pull her out and take her t o school

I must say that I am very thankfully for the help and that I am really proud of our fab team but mostly I can't wait to drive her.. Ohhhboy!

[Jesus_man]

Whew - that was a nice easy fix. Nice work Viper!

Hope the updates to this thread are cool mods from now on!

[hockeydad4-22]

Realized that I have not yet posted the vid of the first time we fired her up.



My bad guys

[hockeydad4-22]

YEEEEEEESSSS!!!!!!

pulled her out of the garage for the first time in over 3 month and took a few joyous grin filled trips around the block this evening.

Need a new upper radiator hose and I am not 100% confident in the power steering pump

Oh yeah, and a complete exhaust, but for a short shakedown test run.... she ran awesome

I guess I will have to open a utube account to show the video.... Oh well, you guys will just have to wait till you can check her out in person

[Rox Crusher]

Congrats HOCKEYDAD and crew !

You guys out a lot of work into a unique configuration.

It should be a stump puller for sure !

[Kinder]

Congrats! I'm excited to see it in person and go along for a ride.

[akaFrankCastle]

Now that you've given up the 4.9 for Drew, you should pick up that 6BT for sale on CL right now and one up, er, TWO up Kinder with the BSD!

[hockeydad4-22]

As some of you know - Drew's rig has not been running properly the last week or so, and slowly it has been getting worse and worse. No power, sputter, hesitating etc. First time it happened, I found one of the fuel line clamps was lose and was leaking... ugh!!!

But it kept happening, to the point where last week he had to drive to school in low range and home again. So I pulled the codes. Came up with and O2 sensor issue, trans overdrive (which we do not have) and some other seat belt switch or something. Kinder came over to play in the garage Saturday and try to troubleshoot the thing. Checked for vacuum leaks, nope all good there. We replaced the O2 sensor - no difference. Checked the fuel pressure - just fine...

Only thing left is injectors right?

So I pulled the intake off, fuel rail and injectors and cleaned them up real well, even soaked them overnight in BG 444 (Saw it on the internet so it has to be true, right?). Then I put a new fuel filter the size of a coffee can inline under the truck. I blew the fuel lines out from the filter to the intake so all clean again.

Sunday morning I cleaned the injectors even more, blew concentrated air at 75 psi through them both ways, replaced the O-rings and seals and put her all back together. Sunday afternoon I took her for a spin and guess what?

All good again.

I then put the BG444 in the gas tank - no sense in wasting it - that stuff is expensive.

If it happens again - I am getting new injectors but the price for them is nearly $350 for all 6 and that is simply not in the budget today.

Pictures:

Before the tear down:

How this didn't leak is beyond me...

Upper off, now mind you - this is the deepest I have ever been in this engine, never even removed the fuel rail previously.

Going to be extra careful with these connectors, I am getting tired of wiring isuses

Fuel rail and injectors removed:

First I cut some fuel line that fit over the injectors and poured some BG-444 into each line, topping it off and let them set for 3-4 hrs. From what I saw on the internet if any of the levels changed that is a sign that injector is stuck open. I left them in the rail as a stand (yes I saw this on the iterweb too...)

All good with the first soak so I pulled all the O-rings off and put them in a can full of the same BG-444 (this is what I saw too....) and let them soak overnight.

Before the overnight soak this is what they looked like, O-rings intact and all:

O-Rings off and ready for the soak:

Post soak and getting the new O-rings and seals. 3 done, 3 to go.

And then..... after about 3 more hours
My work was done

[Jesus_man]

Whew! I misread your post at first saying it happened again after the injector bath. But you said "IF". Anyway, hope it's all good for a while now! Did you try www.rockauto.com for a price check?

[Moab Mike]

Used injectors can be had from the PnP for $10 a piece.

[landshark]

you can rebuild the injectors.. they make a kit check out

http://www.mrinjector.us/

Rebuilt mine on the 76...

[ZOSO]

there used to be a local guy that was doing them. Not sure if he is still around.

Apex Injector Service
Lakewood, Co
303-985-3799
Bob David

$18 an injector for full-service: details in gtsbob's post below.

1-2 day turnaround.

[hockeydad4-22]

First real road test since it appears we have worked out most of the bugs with the 4.9L. Drew drove her to Lyons for the flood recovery volunteer day. According to the math - it sure looks like he got damn near 18MPG!!!

Now I was not there for the fill up on the way home but he said just over 10 gal and trip total was 184 mi from fill up in the AM to fill up in the PM. If this checks out a few more times - I can tell you I will be seriously thrilled!!!

Next up - re-gearing. The 3:50 gears just are not getting her moving with any type of get up and go at all (of course with mileage like that listed above, it might be worth it....).

[Viperwolf1]

Pretty good mpg's. As for the gearing, just remember, less torque=fewer broken parts

[Justin]

Right on! Glad you guys got it sorted.

[Viperwolf1]

How's the trans working?

[hockeydad4-22]

Spent today draining fluids and removing to T-case so hopefully tomorrow I can open up the trans and with any luck at all, I can find/fix the park pawl issue.... If so, then put it back together and back on the road...

If not, we are talking about taking it anothe direction, perhaps even finding another ZF and going 5 speed instead

[hockeydad4-22]

Well, the auto is gone, in its place now sits a NP435 4 speed.

Pulled the C-4, traded it for the 4spd brand new clutch,pressure plate, gear banger,etc. Drew and I struggled with it a few times over the summer and finally recruited some more experienced help. Kinder came over one evening after work, gave us some direction, then this evening Landshark came over and we got her home, bolted up. Thanks guys for all your help. I should have it done and on the road tomorrow as long as I scan source one of these brackets. IF you have one you do not need, please let me know


Otherwise I am going to start searching PnP's up here

[hockeydad4-22]

FINALLY!!!

Completed the C4-NP435 swap yesterday. Everything seems ok. I need to trace down an issue with the turn signals and head lights. Other than those two minor items, she is back on the road. Just in time too. Nearly Rifle elk season and that rig will come in handy.

Now I hope I can finally get back on Wilma....

[Rox Crusher]

Awesome !

Wilma has gone without attention for so long, I wonder if she will be a little tough to deal with at first ?

[hockeydad4-22]

Well I promised Drew I would attempt to sort out some electrical gremlins for him while he is away at boot camp. So today I re-wired his electric fan and then started to look under the dash. I seems that every time he changed radio stations, he ran another wire or two, the issue being 1/2 of them are live and shorting out, causing fuses to burn or even over loading circuits (hence the small fire he had in the fan wiring.

So I just spent half a day pulling the whole dash so I can see what I am up against. Just in case you are wondering... Pulling the dash is a pain in the ass too.

But it's a good thing I pulled it, I now know why the defrost never worked well. Some PO decided that dryer vent would be a good choice in lieu of proper defrost ducts. Unfortunately this person also thought hose clamps turned the wrong way would be good too... Between the folds and excess length defrost never really worked well. So I will fix that, I will also purchase a new glove box (we knew his was thrashed), looks like a wiper switch as well. I will tidy up all the connections, delete all the extra wires and who knows, may even hook up the stereo correctly for a change, wire it to start with the key...

So Monday a trip to the hut for some parts, a stop at the pars house for wire, connectors and the like.

Tomorrow I will get started deleting excess wires and identifying those that actually do belong and hopefully start eliminating potential fire hazards

Here are some photos for all you visual guys.

[D&D72]

Been going through the same with mine, those defrost ducts were hard to slip on even with the dash pulled back.

[Kinder]

Oh how I dislike going behind the dash, and why oh why do all teenage boys jump in there with a pocket knife and electrical tape. Remember TFB and the fuse block, "It's good enough dad!"

[hockeydad4-22]

Drew and his little pony are settling in just fine in the California sun. Too hot in the garage so he pulled her up under a shade tree in the yard to put the bikini top on.

Some things the Marines can not change

Loaded everything including the bronco on my pick up and hauled it to 29 Palms. Loaded to the max the trip took us over 20 hrs of driving not including the 4 hrs lost to buy a new tire thanks to some garbage on the highway, other than being slow, everything went great

[Jesus_man]

That's quite a journey!! Glad it went well aside from the tire!

[Kinder]

Glad your trip was a success, that is one fully loaded truck.