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Discussion Starter · #81 ·
I had the shop resurface the flywheel.


 

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Discussion Starter · #82 ·
This Exedy clutch is great, except for the throwout bearing retainer clip. See that little flimsy piece of aluminum in the center? We crushed that piece up against the transmission shaft when dropping it in. I had to order the ACT Monoloc to replace it, and I'm glad that I did. The ACT Monolock is made out of steel, is one piece, and a much better design all together. Exedy should offer a performance package that includes that instead of their stock junk.


 

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Discussion Starter · #83 ·
Now for the drop.

I did not disconnect the transmission. I ended up dropping the front axle. It was still tight. The exhaust manifolds don't like the bell housing of the transmission. The transmission shift wants to rip into the clutch. The engine mounts want to dig into everything. It took weeks to get it in. So much pushing and shoving.





 

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Discussion Starter · #84 ·
When the clutch bearing quick connect ring broke, I had to wait a week or so for the ACT Monoloc to get in, so I decided to tackle the heater core and install the newer carpet and SLX interior.

I used a rodeo heater core, and cut a hole in the stock heater to accommodate for the difference in pipe location.



















 

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Discussion Starter · #85 ·
I was hoping to have it done before Radwood back in December. I got to about another 8 hrs worth of work of that.




Also, the engine hoist hooks bent, and I broke off the sensor when bolting on the mix chamber...

 

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Discussion Starter · #86 ·
Maiden voyage went well.



So I slapped on the ole Paris/Dakar Badge



And some fresh 285/75/r16 KO2s

 

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Discussion Starter · #87 ·
Looking alright, but let's add those Old Man Emu suspension bits on.





 

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Discussion Starter · #88 ·
Fresh AMSOIL to polish up the breakin period.

 

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Discussion Starter · #89 ·
While we're at it, some Trooper Yakima snowboard rails would be nice too.

 

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Discussion Starter · #90 ·
Let's update my last to do list (the new u joints and fresh transmission oil helped a lot):

- Things that still need work
--- It's leaking oil :( (I don't want a freshly rebuilt engine to leak oil)
--- I have a weird idle pattern. Need to check the wiring on the TPS, IACV, and MAP sensors. Going to have a professional check for vacuum leaks
--- I buggered up the ac controls for the vent position. Also the light doesn't come on for the AC when the button is pushed in.
--- One of the belts needs a little tightening
--- One of the doors still needs the interior handle to be attached
--- Heated seat doesn't work and the light doesn't come on for the switch on the driver's side
--- Safety belt ends don't match up and need to be changed on the rear seats.

- Other things that I have to do.
--- Change out the break in oil.
--- Change the fluids on the transmission, transfer case, and differentials
--- Install OME springs and shocks
--- Install new front sway bar and bushings
--- Change the U joints (I have driveline shunt)
--- Have the AC coolant charge checked
--- Install new CVs (my outer boots are torn and no longer contain bearings)
--- Install new rotors and brake pads
--- Swap in my Aisin Manual hubs
--- Install the Yakima roof racks
--- Have the stereo seated properly (upgrade the speakers too?)
--- Grease the wheel bearings

-Extended to do things
--- Rear cupholder
--- Rear gate handle
--- Trunk handle bars
--- Map lights
--- Compass/temperature reader
--- New bumpstops
--- Fabricate rear lock/unlock button in trunk area
--- Custom Y pipe and new muffler
--- Snorkel
--- Bumper guard / new bumpers????
--- Upgrade to HD tie rods
 

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Discussion Starter · #91 ·
It's been a bit, so here's a fresh update:

My new IACV leaks air, and stalls at cold, but it is set and doesn't keep the RPMs at ridiculous numbers. My AC condenser is cracked. My AC compressor has a wobble. My engine leaks oil out the front when under pressure, so it's probably the oil pump, which is a pain, because I just built the engine....

Here's the list update, I've actually made quite a bit of progress.

- Things that still need work
--- It's leaking oil :(
--- I have a weird idle pattern. Need to check the wiring on the TPS, IACV, and MAP sensors. Going to have a professional check for vacuum leaks
--- I buggered up the ac controls for the vent position. Also the light doesn't come on for the AC when the button is pushed in.
--- One of the belts needs a little tightening
--- One of the doors still needs the interior handle to be attached

--- Heated seat doesn't work and the light doesn't come on for the switch on the driver's side
--- Safety belt ends don't match up and need to be changed on the rear seats.

- Other things that I have to do.
--- Change out the break in oil.
--- Change the fluids on the transmission, transfer case, and differentials
--- Install OME springs and shocks

--- Install new front sway bar and bushings
--- Change the U joints (I have driveline shunt)
--- Have the AC coolant charge checked
--- Install new CVs (my outer boots are torn and no longer contain bearings)

--- Install new rotors and brake pads
--- Swap in my Aisin Manual hubs
--- Install the Yakima roof racks

--- Have the stereo seated properly (upgrade the speakers too?)
--- Grease the wheel bearings

-Extended to do things
--- Rear cupholder
--- Rear gate handle
--- Trunk handle bars
--- Map lights
--- Compass/temperature reader
--- New bumpstops
--- Fabricate rear lock/unlock button in trunk area
--- Custom Y pipe and new muffler
--- Snorkel
--- Bumper guard / new bumpers????
--- Upgrade to HD tie rods
 

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Discussion Starter · #93 ·
TheSecretSavage said:
What year of SLX? I'm looking to get new front seats and replace my glove box.
I think it was a 96. Any SLX interior will work with a 95 onward Trooper interior.
 

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Discussion Starter · #94 ·
Okay, another update:

My oil leak was from a bolt that I left out of the oil pump. It was one of the bolts that holds on the wand that goes down to the oil filter. I put a new bolt on, and that fixed my leak.

The shop said all of my AC parts were leaky or going bad, so I am replacing or have replaced the condenser, evaporator, compressor, expansion valve, and am thinking about cleaning the blower fan, because it's not blowing quite as strong as I'd like.

All of my speakers work, but I think I have some shorts at the actual stereo plug. I may just buy a new head unit and have a shop install it.

I installed some MSD-8224 coil packs and increased my spark gaps to .059 in, as inspired by Brent Tri on Isuzu Trader. I highly suggest this upgrade, as everything seems to have a little more umph.

I have oil for my transfer case and diffs, and stock skid plates to install soon. Looking forward to my first off road trek in the near future.

I also acquired a leather steering wheel. I may try to make a heated steering wheel. I am also contemplating adding stereo control buttons to the back of it.

Here's the list update, I've actually made quite a bit of progress.

- Things that still need work
--- It's leaking oil :(
--- I have a weird idle pattern. Need to check the wiring on the TPS, IACV, and MAP sensors. Going to have a professional check for vacuum leaks
--- I buggered up the ac controls for the vent position. Also the light doesn't come on for the AC when the button is pushed in.
--- One of the belts needs a little tightening
--- One of the doors still needs the interior handle to be attached

--- Heated seat doesn't work and the light doesn't come on for the switch on the driver's side
--- Safety belt ends don't match up and need to be changed on the rear seats.

- Other things that I have to do.
--- Change out the break in oil.
--- Change the fluids on the transmission, transfer case, and differentials
--- Install OME springs and shocks
--- Install new front sway bar and bushings
--- Change the U joints (I have driveline shunt)

--- Have the AC coolant charge checked
--- Install new CVs (my outer boots are torn and no longer contain bearings)
--- Install new rotors and brake pads
--- Swap in my Aisin Manual hubs
--- Install the Yakima roof racks

--- Have the stereo seated properly (upgrade the speakers too?)
--- Grease the wheel bearings

-Extended to do things
--- Rear cupholder
--- Rear gate handle
--- Trunk handle bars
--- Map lights
--- Compass/temperature reader
--- New bumpstops
--- Fabricate rear lock/unlock button in trunk area
--- Custom Y pipe and new muffler
--- Snorkel
--- Bumper guard / new bumpers????
--- Upgrade to HD tie rods
 

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Discussion Starter · #95 ·
The Impossibear Sticker

 

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Discussion Starter · #96 ·
Pictures from the cv / tie rod / shock swap and manual locking hub conversion.











 

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Discussion Starter · #97 ·
June Update:

  • I changed out the diff fluids and the transfercase fluid. I'm pretty sure that transfer case drain plug is stripped, but it's on there and not leaking too much that I can see. I think somebody cross threaded it on, or tacked some thread sealer on it. I might take it back off and put some thread sealer on it as well.
    [/*]
  • I changed the TPS, and that solved so many of my drive line shunt issues! I guess the old one was loose or sticking, but now it shifts so smooth. There's still a little kick, so I'm going to have the shop do a vacuum test.
    [/*]
  • I ordered a new AC compressor, but it was locked up when it arrived. I installed it anyway, not realizing that it was locked up, and had the shop fill it with freon, but they heard it squeal and told me the bad news. Company is sending me a replacement.
    [/*]
  • Had an audio shop install a new alpine head unit for me, so now the speakers are all dolled up. The bluetooth mic isn't working, so I might pull her back and make sure it's plugged in.
    [/*]
  • I installed a map light, but since mine didn't have the wiring, I ran a power wire to the dome light wire. Something is off though, because having both map lights on dims each other, and they don't play nice with the dome light. I'm sure it's a bad connection somewhere, I just don't know where.
    [/*]
  • I'm in the process of getting the compass/temp reader installed. I'm having trouble pushing the wires through the rubber grommet in the firewall where the main cable weave runs through.
    [/*]
  • I have a spare passenger side power lock mechanism that I am modifying for use in the trunk area. I think I've found the wires where they run into the cab, so now its time to run them around the side of the vehicle and to the spot that I want to mount the switch.
    [/*]
  • I received two additional grab bars that I am going to install on the drivers pillar and overhead.
    [/*]
  • I've also ordered a new reverse switch for the MAU5. Somebody disconnected mine along with the 1-2 position switch and the 3-4 position switch. I don't need a shift light, so I'm going to leave those disconnected.
    [/*]
  • I have stock skid plates that I need to clean and repaint before installation.[/*]
Coming close on initial completion, with only light mods left to go.

Here's the list update, I've actually made quite a bit of progress.

- Things that still need work
--- It's leaking oil :(
--- I have a weird idle pattern. Need to check the wiring on the TPS, IACV, and MAP sensors. Going to have a professional check for vacuum leaks
--- I buggered up the ac controls for the vent position. Also the light doesn't come on for the AC when the button is pushed in.
--- One of the belts needs a little tightening
--- One of the doors still needs the interior handle to be attached

--- Heated seat doesn't work and the light doesn't come on for the switch on the driver's side
--- Safety belt ends don't match up and need to be changed on the rear seats.

- Other things that I have to do.
--- Change out the break in oil.
--- Change the fluids on the transmission, transfer case, and differentials
--- Install OME springs and shocks
--- Install new front sway bar and bushings
--- Change the U joints (I have driveline shunt)

--- Have the AC coolant charge checked
--- Install new CVs (my outer boots are torn and no longer contain bearings)
--- Install new rotors and brake pads
--- Swap in my Aisin Manual hubs
--- Install the Yakima roof racks
--- Have the stereo seated properly (upgrade the speakers too?)
--- Grease the wheel bearings

--- Reverse Switch
--- Skid Plates
--- Coil Pack Ugrades

-Extended to do things
--- Rear cupholder
--- Rear gate handle
--- Trunk handle bars
--- Map lights

--- Compass/temperature reader
--- New bumpstops
--- Fabricate rear lock/unlock button in trunk area
--- Custom Y pipe and new muffler
--- Snorkel
--- Bumper guard / new bumpers????
--- Upgrade to HD tie rods
--- Leather Steering Wheel
 

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Discussion Starter · #98 ·
From a few months back. First camping trip was tanked due to a sheared fan bolt. I tried drilling it out, but could not get it. Had some Isuzu friendly help me pull it some weeks later.







 

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Discussion Starter · #99 ·
Cargo Handle Bar Installation. Got a drill bit that was just the right size. Who needs square holes?

These are actually super beneficial if you plan on hanging out in the back. I highly suggest this upgrade.



 

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Discussion Starter · #100 ·
Does anybody have any tips on how to access the key hole when you have a 285/75/16 spare? My tire is too big.

 
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