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Discussion Starter · #1 ·
I've never done a build thread. I really should document everything, I'm trying to get better and keep it current.

It starts off a little over a year ago 11-12-2011. I awoke at 5am and made a 4 hour journey to northern VA to scoop up this craigslist find. It was listed at $950 but he agreed to $750 over the phone. From talking to him, found out the vehicle was working perfect, he came to a stop at a light, when he went to take off it didn't go. He turned it off and when he tried to restart it just a nasty sound. He took it to a mech who looked at it and told him he had a broke crank. For me this is perfect, I've got a great DOHC in a 94 LS beat all to **** vehicle. So I scoop it up and bring it home.





It sits outside for a month or so, in the mean time I pick up a local score 97 seized eng for a good price this joins the 95 and the 94 I already have. I'm begining to have a Trooper graveyard at my shop now. I list them up for parts availability on here, knowing I don't need all these spare parts. Sell a few things. One day I'm talking to a mech friend of mine and he's asking what's wrong with them. I go over what's going on with them and my plans to get the 95 going with the eng out of the 94. He says "you know it's a good possibility the crank's not broke, probably just the flex plate". Well damn, now I'm curious. The next day my employee and I pull it into the shop and proceed to take the trans out. Now we've got a good view of the flex plat and sure as **** you can see it cracked all the way around the hub, but still held in place.



Here comes the real sitting. Our busy season at work had kicked in full steam. We sell and service outdoor power equipment (mowers, trimmers, chainsaws). I just leave the Trooper there in the shop, trans beside it for the entire season, always in the way, but out of the nasty environment here on the east coast. So about a week ago, I decided to start tinkering with it again. I 've been wanting to re-finish the Dakar emblem on the grille, to something to remind me of how I want the build to go. So I remove the grill and take the emblem off and work some magic on it.






I think this sets the tone for me. I plan on keeping the Trooper it's natural white color because it's clean and doesn't need to be painted. However I'm not particuarly fond of the condition of the bumpers and the gold/silver color is chipping off. This will become satin black and textured. I start with the bumpers thinking I'll leave the fenders in place for the painting (I change my mind on that one). I get the bumpers and covers off and realize 1. I like the way it looks without the factory bumers 2. They're not in the best of shape anyways. So bumper's will be built for this later on from bare steel. I go ahead and decide to remove the rest of the trim (man they hold some debris), mainly because I need to replace two pieces that are a little busted (spare vehicle for this stuff)




Now we're caught up to date as of today. It may seem like I'm jumping around on my repairs, well I am. The guy that helped me remove the trans is no longer working for me and I was out of the shop while he unhooked some of it. The said Mechanic that suggested the flex plate said he'd put the whole thing back in hook everything back up for $150. I'm going to let him do that, and help as needed. So I'm tinkering with everything else till we can get a Sunday to knock it out (or in depending on how you look at it). I was thinking I might need to replace the rear main seal while the trans was out. So I got under there today and removed the flex plate so I could inspect the seal. The seal is fine, most of my leaking oil is coming from the topside ie valve covers, nothing horrible but will need to be fixed later. I want to get the trans back in with the new flex plate and make sure this thing operates with out any other problems before I do anything else major to it. I'll keep doing minor stuff in the meantime :lol:

 

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Discussion Starter · #3 ·
my 95's Christmas present came in today :lol:

crazy how thick it is compared to the haynes for my 90
 

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Discussion Starter · #4 ·
Alright, as of now my buddy still hasn't been able to help with the trans. I may tackle it myself. Thinking if I'm going to do this it would be nice to have a little extra room to work. Since I plan on installing a 1" body lift, I decide to go ahead and do that now. I'd already ordered a box of new hockey pucks (if someone needs a 1" BL send me a PM). I've already soaked the bolts as much as possible with blaster, heard I don't want the back 6 to break or it will become a real job :bom: . Ironically the back 6 came out with no problems, the front 6 were the pains with the very front 2 breaking. Not really a big deal, since I've got to get new bolts for the front ones anyways. Typically you use the front 6 in the back, that's what I've got spare Troopers laying around for :lol: time to scrounge up 2 more front bolts. I got the holes drilled in 6 of the pucks and am ready to put those in tomorrow. Think I'm done for the day, need to hit ace for some bolts :D

put the tires back on and got her off the stands


measurement at the passenger rear


always have to break something, 2 in this case


looks like I need a bushing as well, pure nasty :!:


anyone else in the market for a 1" lift. Thanks to "JBsTrooper" for the idea and info on the Hockey Puck lift.


holes drilled in 6 for the drivers side
 

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Discussion Starter · #5 ·
I got to finish the 1" (hockey puck) body lift this afternoon. Everything went pretty good. I was able to get the 2 bolts and 1 body mount bushing asm off of my donor 94 with no problems, there's actually almost no rust on that one.....go figure. I'd say I've probably got 3 hours total in the lift, which I don't think is bad at all. I've got plenty of pucks left if anyone wants an inexpensive albeit small lift. Thinking about adding one to the van, but the wife complains about the step up already :lol:

New grade 8 hardware 7/16 for the front 6 mounts. The very front two had to come in from the bottom, I made sure to use some loc-tite.


It's a pretty good fit. Yes they are made in Canada and my body mounts aren't in the best of shape.


As predicted there's now 7" of clearance where there was only 6" before, not rocket science or anything.


After about a cumulative 3 hrs of work, the Trooper now has a slightly better stance. Plus it'll be easier to re-install the Trans now 8)
 

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nice work. get that in and those flares lined. What's the story with the 98 you got?

" '98 trooper........apparently I'm starting a trooper graveyard"
 

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Discussion Starter · #8 ·
JBsTrooper said:
nice work. get that in and those flares lined. What's the story with the 98 you got?

" '98 trooper........apparently I'm starting a trooper graveyard"
Thanks dude, I'm planning on using the Rustoleum spray liner on the lower third, flares and steel bumpers. Picked up the 98 like a week after this 95, the 3.5 is seized. Less than 100K on it, but there's some body damage and the rust on the frame makes my 90 Trooper frame look like new :shock:. Eventually I plan on pulling the motor and seeing if I can get it going for a reasonable $, if so find a clean 98+ with a blown engine on craigslist to throw it in. Probably keep the trans for a backup, after I check it's inside out.

here's a pic of the "98 Trooper" most of the body damage is on the other side, interior is amazingly clean.
 

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Discussion Starter · #9 ·
bradzuzu said:
Great progress so far ... I like the hokey pucks lol cool man 8)
thanks, :lol: I stole the hockey puck idea from "JBsTrooper " not sure if he came up with it or not, but it's pure genius in my opinion.
 

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So when did the body generation change ?? I had a 93 trooper once upon a time , red Infact .. The wifey didn't like the lifter tick and stuff so it got traded :( .. Anyway it was the new body style just not all dressed up , right ??
 

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Discussion Starter · #11 ·
92-94 newer rounded body style.
95-97 same body style but added track width and fender flares
98+ was the final body change

so I just realized that means I have one of each :lol: and the only one currently running is the gen 1
 

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Discussion Starter · #12 ·
Test mounted the ARB today after toying with the idea of putting it on the '90. Obviously I'll have to raise the mounts up 1" due to the body lift, but that looks pretty straight forward. The trans temp gauge came in today as well, so I can install the sending unit on the trans then finally get that back in (been a long time coming).

goodies!


test fitting the ARB


I'll have to remove these in order to install the bull bar mounts, no biggie I love using cutting tools :D


family shot with a teaser of what the ARB is going to look like mounted (but up 1 more inch ;) )
 

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foytiX said:
bradzuzu said:
Great progress so far ... I like the hokey pucks lol cool man 8)
thanks, :lol: I stole the hockey puck idea from "JBsTrooper " not sure if he came up with it or not, but it's pure genius in my opinion.
i'd love to take the credit for that idea, but i stole it from a guy on NC4x4.com. Love the garage
 

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Discussion Starter · #15 ·
Not much rust at all on that one. Picked that one up from western part of VA. It hasn't been subjected to decades of salt on the obx yet :lol:
 

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Discussion Starter · #16 ·
Got a buddy coming to help install the trans in the AM. Now I've just got to hope the flex plate was the only problem. I'm glad to be going on this project again.
 

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Discussion Starter · #18 ·
bradzuzu said:
Sweet !! Get er done ... In thinking the torque converter bolts will suck !! Be safe and have fun..
Yea, as I recall they weren't too fun to get out, doesn't look any easier going in :lol:
 

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Discussion Starter · #19 ·
Well, that was a nightmare and still only about 90% finished. We were having the biggest problem getting it lined up and tightened down, lo and behold the converter came out of the pump (we originally checked to make sure it was seated). We knew something wasn't right before we tightened it all up and tried to turn the crank with a breaker bar, no go. We installed two 4" long m12x1.75 bolts, and removed the rest. Slid the trans back far enough to figure out the problem. It all went back together so much better after that. Getting the bolts in the converter wasn't too bid a deal, a couple of extensions over the axle tube and through the starter hole. We got it buttoned back up good enough to test the eng and trans. She fired up no problem, all the gears checked out (didn't drive more than a foot though). Next week sometime I'll, finish installing the exhaust and replacing all the hardware that is left out. Seems like we are going to be an all go, when I get all the small stuff buttoned back up :D
 
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