1997 Passport maintenance, upgrades, and adventures!

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Re: 97 Passport maintenance and upgrades [pic heavy!]

Postby amd_h4x0r » Sun Jun 05, 2016 10:38 pm

just a bump to let you know the Assport is still kickin & tickin :)
Watch on youtube.com
1997 "Assport" - 3.2L V6, 5 SPD, 4x4, 197k miles
3" shackle/add-a-leaf lift --- 3" torsion bar crank --- ball-joint flip /spacer
265/75R16 Pirelli Scorpion MTR on 16x8 U.S. Wheel 94 Series rims --- Aisin manual hubs
Aussie locked front & rear --- Independent4x HD tie rods --- custom prerunner bumper -- Smittybilt XRC8 winch
Flo-Pro V Force exhaust (RIP) --- cone filter --- custom faded paint w/lots of dents & scratches
Videos: http://www.youtube.com/user/amdh4x0r
My other moneypit: http://www.powerstroke.org/forum/member ... =1#aboutme
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Re: 1997 Passport maintenance, upgrades, and adventures!

Postby amd_h4x0r » Mon Feb 11, 2019 11:57 pm

So after 11 years of abuse the ol' Assport is just shy of 200k miles. The 3.2 still ticks like hell and leaks oil out of every gasket & seal it seems. The exhaust is falling apart and god knows when (or if) the timing belt was changed (I never have). In the past year or two so I've replaced all the suspension bushings, shocks, steering components (tie rod ends, center link, idler arm, power steering unit), ball joints, front wheel bearings/seals/half-shaft bearings, rear drive shaft u-joints & carrier bearing, and probably more that I can't remember. Now it's time to give the 3.2 the care it deserves.

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Last edited by amd_h4x0r on Tue Feb 12, 2019 12:14 am, edited 1 time in total.
1997 "Assport" - 3.2L V6, 5 SPD, 4x4, 197k miles
3" shackle/add-a-leaf lift --- 3" torsion bar crank --- ball-joint flip /spacer
265/75R16 Pirelli Scorpion MTR on 16x8 U.S. Wheel 94 Series rims --- Aisin manual hubs
Aussie locked front & rear --- Independent4x HD tie rods --- custom prerunner bumper -- Smittybilt XRC8 winch
Flo-Pro V Force exhaust (RIP) --- cone filter --- custom faded paint w/lots of dents & scratches
Videos: http://www.youtube.com/user/amdh4x0r
My other moneypit: http://www.powerstroke.org/forum/member ... =1#aboutme
User avatar
amd_h4x0r
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Posts: 293
Joined: Sun Jun 22, 2008 6:59 pm
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Re: 1997 Passport maintenance, upgrades, and adventures!

Postby amd_h4x0r » Tue Feb 12, 2019 12:05 am

As you can see, the rotating assembly seems to be in great shape. There's hardly any lip on the upper cylinder walls and you can clearly see the crosshatching is still present. I still need to take cylinder measurements, but I can probably get away with a quick hone and re-ring. I forgot to take pictures of the pistons, rods, bearings, and crank journals but they are all very clean as well. I'll get some added soon.

THOSE MAIN CAPS ARE BEEFY!!
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Last edited by amd_h4x0r on Tue Feb 12, 2019 12:15 am, edited 1 time in total.
1997 "Assport" - 3.2L V6, 5 SPD, 4x4, 197k miles
3" shackle/add-a-leaf lift --- 3" torsion bar crank --- ball-joint flip /spacer
265/75R16 Pirelli Scorpion MTR on 16x8 U.S. Wheel 94 Series rims --- Aisin manual hubs
Aussie locked front & rear --- Independent4x HD tie rods --- custom prerunner bumper -- Smittybilt XRC8 winch
Flo-Pro V Force exhaust (RIP) --- cone filter --- custom faded paint w/lots of dents & scratches
Videos: http://www.youtube.com/user/amdh4x0r
My other moneypit: http://www.powerstroke.org/forum/member ... =1#aboutme
User avatar
amd_h4x0r
Trail Rider
 
Posts: 293
Joined: Sun Jun 22, 2008 6:59 pm
Location: IL
Has thanked: 1 time
Have thanks: 2 times

Re: 1997 Passport maintenance, upgrades, and adventures!

Postby amd_h4x0r » Tue Feb 12, 2019 12:10 am

The bad news is that the upper valve train has issues (no surprise). I found 2 collapsed hydraulic lifters, and the intermediate rocker arms & shaft for the exhaust valves are wrecked on both heads.
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1997 "Assport" - 3.2L V6, 5 SPD, 4x4, 197k miles
3" shackle/add-a-leaf lift --- 3" torsion bar crank --- ball-joint flip /spacer
265/75R16 Pirelli Scorpion MTR on 16x8 U.S. Wheel 94 Series rims --- Aisin manual hubs
Aussie locked front & rear --- Independent4x HD tie rods --- custom prerunner bumper -- Smittybilt XRC8 winch
Flo-Pro V Force exhaust (RIP) --- cone filter --- custom faded paint w/lots of dents & scratches
Videos: http://www.youtube.com/user/amdh4x0r
My other moneypit: http://www.powerstroke.org/forum/member ... =1#aboutme
User avatar
amd_h4x0r
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Posts: 293
Joined: Sun Jun 22, 2008 6:59 pm
Location: IL
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Re: 1997 Passport maintenance, upgrades, and adventures!

Postby amd_h4x0r » Sun Jan 05, 2020 4:22 pm

After a 9 month struggle to get a 3rd party to correctly work the block, heads, and crank, I finally got everything back around the end of November. Assembly has been underway for about a month!

  • the block was oversized .040
  • 6x new .040 pistons w/ rings
  • the crank was polished and remains stock size
  • I am reusing the stock connecting rods
  • the heads were resurfaced and have new valve stem seals
  • 2x new intake rocker arm shafts
  • 2x new exhaust rocker arm shafts
  • 12x new intermediate rocker arms
  • 12x new intake rocker arms
  • 24x new hydraulic lifters
  • 6x new fuel injectors
  • new oil pump
  • new water pump, timing belt, and tensioner/pulley
  • new 170 degree thermostat
  • all new seals, o-rings, and gaskets
  • new bearings for a/c pulley and tensioner
  • and more as I remember them!

It looks like Photobucket is currently having issues, so I'll add pictures once they are back online. For now here's a couple videos.

Watch on youtube.com

Watch on youtube.com

Watch on youtube.com

Watch on youtube.com
1997 "Assport" - 3.2L V6, 5 SPD, 4x4, 197k miles
3" shackle/add-a-leaf lift --- 3" torsion bar crank --- ball-joint flip /spacer
265/75R16 Pirelli Scorpion MTR on 16x8 U.S. Wheel 94 Series rims --- Aisin manual hubs
Aussie locked front & rear --- Independent4x HD tie rods --- custom prerunner bumper -- Smittybilt XRC8 winch
Flo-Pro V Force exhaust (RIP) --- cone filter --- custom faded paint w/lots of dents & scratches
Videos: http://www.youtube.com/user/amdh4x0r
My other moneypit: http://www.powerstroke.org/forum/member ... =1#aboutme
User avatar
amd_h4x0r
Trail Rider
 
Posts: 293
Joined: Sun Jun 22, 2008 6:59 pm
Location: IL
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Re: 1997 Passport maintenance, upgrades, and adventures!

Postby amd_h4x0r » Mon Mar 15, 2021 10:12 pm

I just realized I never finished updating my build so here's some more pictures and videos.

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Last edited by amd_h4x0r on Mon Mar 15, 2021 10:14 pm, edited 1 time in total.
1997 "Assport" - 3.2L V6, 5 SPD, 4x4, 197k miles
3" shackle/add-a-leaf lift --- 3" torsion bar crank --- ball-joint flip /spacer
265/75R16 Pirelli Scorpion MTR on 16x8 U.S. Wheel 94 Series rims --- Aisin manual hubs
Aussie locked front & rear --- Independent4x HD tie rods --- custom prerunner bumper -- Smittybilt XRC8 winch
Flo-Pro V Force exhaust (RIP) --- cone filter --- custom faded paint w/lots of dents & scratches
Videos: http://www.youtube.com/user/amdh4x0r
My other moneypit: http://www.powerstroke.org/forum/member ... =1#aboutme
User avatar
amd_h4x0r
Trail Rider
 
Posts: 293
Joined: Sun Jun 22, 2008 6:59 pm
Location: IL
Has thanked: 1 time
Have thanks: 2 times

Re: 1997 Passport maintenance, upgrades, and adventures!

Postby amd_h4x0r » Mon Mar 15, 2021 10:13 pm

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Watch on youtube.com

Watch on youtube.com
1997 "Assport" - 3.2L V6, 5 SPD, 4x4, 197k miles
3" shackle/add-a-leaf lift --- 3" torsion bar crank --- ball-joint flip /spacer
265/75R16 Pirelli Scorpion MTR on 16x8 U.S. Wheel 94 Series rims --- Aisin manual hubs
Aussie locked front & rear --- Independent4x HD tie rods --- custom prerunner bumper -- Smittybilt XRC8 winch
Flo-Pro V Force exhaust (RIP) --- cone filter --- custom faded paint w/lots of dents & scratches
Videos: http://www.youtube.com/user/amdh4x0r
My other moneypit: http://www.powerstroke.org/forum/member ... =1#aboutme
User avatar
amd_h4x0r
Trail Rider
 
Posts: 293
Joined: Sun Jun 22, 2008 6:59 pm
Location: IL
Has thanked: 1 time
Have thanks: 2 times

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