Take a Break

Well, bummer. Didn’t get Dookie fired up yesterday like we hoped, but instead had to load up Klooge so Dave could head back home to Phoenix today. We got pretty close, though.

No pics, as we were super-busy all day. Had to knock out one of the freeze plugs after all, and it looks like it might not be a bad idea to get the rest of them at some point soon as it was paper thin and started dripping as Dave was adding coolant. Fortunately, it was the rear-most on the passenger side, so the engine mount wasn’t in the way – pop the starter off, knock it out, tap a new one in, and we’re all done about 20 minutes later. Easy-peasy. The rest seem to be hanging in there and there were no other [coolant] leaks we could see, so that’s a plus.

I had to chase some 90-degree male AN fittings, since the straight one from the sump kit won’t work with the aftermarket Sanden compressor (as I mentioned in the thread above). The fittings needed to be heated and pressed onto the hoses, which I’d never done before, but it was easy enough… although, I did get a ‘practice run’ in since I cut the sump’s ‘In’ hose (from the lift pump) too short. Fortunately, Edelbrock provided enough hose for me to recover from my mistake.

Dave picked up another set of spark plug wires, but those turned out to be ‘cut-to-fit’ as well, and he already had them made up by the time I’d gotten up around 0900. I’d been up until 0130 the night before trying to get the A/C to blow cold air again. He’d gotten a lot of the final things ready to go while I was chasing the AN fittings and grabbing some breakfast.

The house A/C had also been having issues the past few days, which started out as being a clogged air filter that I’d changed out the night before last. We normally got about 9 months out of our 4″ thick HEPA filters, but since we got the dogs last summer, that’s no longer the case. I’d changed it out a few months ago, but it needed it again and I wasn’t paying attention (a little pre-occupied). The evaporator iced up solid, blocking the airflow to the vents, and I noticed the compressor had iced up as well, so I called a HVAC tech to come service the unit. After explaining what happened, what I’d done, and that my efforts to thaw out the compressor weren’t working, he discovered the compressor’s contactor switch burned up while it was running, which caused the evaporator to ice-up solid, along with the compressor in the outside unit because it just never quit running. That explains why the evaporator wouldn’t thaw out while I was just running the fan, despite ‘faking out’ the NEST “Smart” thermostat (which ain’t so ‘smart,’ after all… it won’t even let you turn on JUST the fan without being in Heat or Cool mode – I put it on Heat and cranked the temp way down, so the furnace wouldn’t kick on). The HVAC tach said I’d done everything perfectly, but the contactor switch failing was the unknown variable I was up again. FORTUNATELY, he replaced the contactor switch (told us to let it all thaw out and call him if there were any issues) and everything eventually thawed out last evening, the house cooled back down to normal, and no other issues cropped up with the A/C, so I got away with ‘just’ a $230 bill for my bonehead mistake.

Later in the afternoon, a friend Harry showed up with Dave’s trailer – he’d been kind enough to let us store it in his [huge] back yard while Dave’s been here. Harry was bummed because he thought he’d lost one of the ramps – there are 2 storage compartments for the ramps with doors on the back end underneath, but one of the doors had lost a locking pin and was hanging wide open. So, we threw in the towel on getting the Jeep fired up and did a quick retrace of the path between Harry’s and my house with no joy. I asked to stop by the trailer one last time to check things out, and I slid my hand into the compartment to find that the ramp had gone in a lot farther than expected. WHEW!! No lost ramp! Dave and I made a run over to Tractor Supply and picked up some new locking pins, so hopefully there won’t be any more issues with those ramp storage doors popping open.

Even later, I made a run to Jason’s Deli for dinner, and they hosed me out of my sandwich on the order – my wife was pissed, but I’m like, “We just avoided a major catastrophe with the HVAC and avoided having to replace a lost trailer ramp… if Karma wants to keep a sandwich for itself, Karma can have my sandwich.” Besides, I still have a ton of sandwich-makin’ stuff in the fridge to finish off – had to keep Dave properly fed and watered while he slogged away on my Jeep, after all.

OK, so now I just need to finish wiring up a few things, install the brake pedal assembly so I can hang the steering column, grab some gas, and give it all another once over before turning the key. But that’ll have to wait until tomorrow, since I feel like a twisted mess right now after crankin’ on the Jeep for the past two weeks straight. I need a break, so I’m just going to chill for today.

I already miss having Dave here (we go back a long way – almost 30 years) and just like with most military folks, it’s always hard to say goodbye and even harder to keep in touch. We’ve done well at that this whole time and get together when we can. I’m just happy Dave was able (and willing) to make the trip to help get Dookie back to good. Hopefully [sooner than later] I can get the chance to visit Dave in AZ, with Dookie on a trailer, and go cruizing on some of those cool trails out that way. Couldn’t have done it without ya, Brother! Thanks again!!


Day Ten

Got the driver side header on, followed by the transmission mount, exhaust, and skid plate, in that order. Then, added some hoses, plumbing for the fuel injection pump, and mounted the Holley Mighty Mite electric fuel ‘lift’ pump that supplies the fuel injection system’s high pressure pump. Went to put on the upper radiator hose and noticed the cool bracket I’d made for the coil was right in the way. After a bit of head scratching, came up with a new solution that I’ll work on later, but it’s just hanging there for now so we can get it running tomorrow. I also nailed down the old valve covers (for now) since the new ones didn’t come with gaskets (thanks, Edelbrock) and started down the rabbit hole of the Accel Cut-To-Fit wires, but discovered that’s going to be an all-day sucker project, so we’ll toss on some pre-made wires just to hear it run tomorrow. I’m SO glad Dave’s here – I wouldn’t have gotten anywhere close to this point on my own.


Day 9

Made some more progress today. Got the Pro Flow intake harness plugged in (I’ll tidy up the runs later). Also figured out there was no place to mount the coil, so I fabbed a bracket to take advantage of the spare mounting points on top of the Sanden air compressor (test-fit with the coil in-place – I’ll paint it later, too). I worked on the engine harness a bit while Dave was busy underneath reinstalling the transfer case shifter, new transmission mount, and drilling out a snapped-off bolt Tom’s Tire World left me after installing the lift kit back in ’96. Toward the end of the afternoon, Dave installed the spark plugs and the passenger side header along with getting its pipe drilled for the O2 sensor. The worm gear clamps for the FAST O2 sensor ‘Strap-On Bunghole’ ran out of slots, so we had to make a run for some more clamps and a few more nit-noids. Hopefully tomorrow, get the other header and exhaust pipe in, reinstall the skid plate/transmission mount, and finish up the fuel system and wiring, along with hoses. Then brake pedal assembly and steering column and hoping to hear it run sometime on Friday with any luck.

Everything except the coil wires and Mass Air Temp sensor are plugged in – I’ll re-route them to make it pretty after I hear it run.
Installed the oil fill neck and breather cap, along with a bracket for the coil I made for the top of the air compressor.
Wow – those headers look awesome! Still need to get the heater hoses plumbed and finish up the A/C hoses (after the new valve cover goes on).

Day 8

Today was mostly underside stuff, so no pics of that. Here’s the Edelbrock high pressure fuel pump to feed the Pro Flow 4 MPFI sitting on top of the engine I mounted up yesterday. Dave got the torque converter bolts sorted out, and with the exception of the transfer case shifter, we’re ready to hang the exhaust and replace the transmission mount (underneath). I was on the phone with Scorpion Racing Products about the rocker arms (asking which studs I need to fit their roller rockers, and Norm suggested he could send some pedestal-mounted roller rockers to preclude the need for studs. So, we’ll be blowing off the roller rockers until the trial ones show up and I can see if they’re going to work (or not). After that, I tore into the Redneck’d wiring harness that came from Klooge, removed the Duraspark circuits, and got most of the leftovers identified and marked, now just need to figure out what the remaining 4 or 5 wires that had been clipped go to, repair them, then wrap the whole thing so it looks nice with all the new Edelbrock wiring I’ll start installing tomorrow.


Day Seven

After yesterday’s Cars & Coffee wiped us out, we started working on the top end (since the new shifter cable won’t be in until Monday-ish), and one of the intake manifold bolts decided to snap off… I won’t say who did it, but it wasn’t me. LOL! So, the better part of the afternoon was tracking down bolt extractors, and once that was done, we were done. Today started with pulling the intake, cleaning up the valley, harvesting some bits off the old intake we might need, and some overall general housekeeping before installing the intake, new distributor, and a good portion of the fuel injection system (OK, it was already loaded up on the intake, but it sounded huge). The shifter cable actually showed up yesterday as well – Bonus!

Pulled the old Edelbrock Performer intake and found this. Not so bad… of course, the water jackets on the back end were clogged, so hopefully they’ll work again after a good cleaning.
Here’s the one that didn’t make it. I’m thinking of cleaning it up, drilling a hole, and getting a nice chain to make someone a necklace. In all fairness, it was next to the front water jacket, so it probably didn’t have a chance of coming off in one piece, anyway.
All cleaned up and ready for the new intake. Gonna pull off the valve covers to load up the new Scorpion 1.7 roller rockers on 7/16″ screw-in studs.
After discovering the rocker studs I ordered were the wrong ones, we pushed through to get the new intake on. Looks pretty awesome!
Set the old valve covers on to keep stuff out of the rockers while we work on replacing the distributor.
Even though I’m a staunch believer in Duraspark, the fuel injection system came with this HEI distributor which is controlled by the ECU. I hope this thing runs as well as I think it will.

Day Five

Finally, some actual progress. Started in on getting the transmission cooling lines plumbed for the radiator-side, and ran into a major snag that had us chasing fittings late Wednesday, yesterday, and early this morning. After no joy actually taking the radiator to O’Reilly’s for some help, Dave noticed something about the fittings just before we left, and wound up going a whole different direction, and put an end of the ATF cooling line slog. Once we got the ATF cooling lines plumbed, jumped over to the oil pump and oil pressure sending unit. As I was getting ready to start in on the shifter cable, I noticed it’s for a GM 700R4/TH400… which is not an AMC TF999, so I ordered a new shifter cable kit from Summit and it’ll be here [hopefully] Monday. Hit some more tomorrow (probably top-end: intake manifold, fuel injection, and roller rockers).

Pic from the other day when Dave got the power steering pump installed… just gotta plumb it back up now.
Here’s the first attempt at adapting the radiator’s cooling line flare fitting using the adapters they sent with the radiator. No Go – this comes up too close to the top of the sway bar.
Here’s the solution to the sway bar interference issue. Little did we know that one of those fittings was correct in its size, but didn’t fit, and the other was ‘smaller’ but did fit. Took us WAY too long to figure that out. Regardless, a 90 degree fitting is needed here to keep the lines off the sway bar.
After 2 days of chasing fittings, we came up with a completely different set of fittings that worked. Dave’s ‘Mark-1 Eyeball’ saw that the ATF Cooler inlets also had female threads, so rather than using the adapters that came with the radiator, we went that route, and now it’s all good.
Dave got the oil pump installed while I worked on coming up with a solution for the oil pressure sensor. The previous owners had a redneck-engineered solution that had both electrical and mechanical oil pressure sending units, but the oil pump line had broken off a LONG time ago (which is likely why the engine and transmission were caked in oil when I got it). Dave’s ‘Mark-1 Eyeball’ saved the day again when he noticed one of the oil pump drive gears had popped out and landed on top of the front axle housing.
Got some new power steering pump hoses at O’Reilly’s, but the pressure line didn’t work. Turns out, the pump has a bolt-on stinger for the old hose that wouldn’t work with the new hose. But, I can remove the stinger if needed, so I’ll keep the new hose as a spare and hope the old hose hangs in there.
“Dave was here – 2022.” Something of a tradition started by my old friendĀ Jim Eimer.

Day Three

No picture updates today, but Dave got the power steering pump installed and plumbed while I farted around trying to organize (read: find) some of the parts I’d ordered awhile back, and the container with all of the fasteners I’d removed while cleaning the engine. That was after chasing down a few parts: hoses, belts, fasteners, and some 5/16″ barbs for the radiator (the Inline Tube transmission cooling lines don’t have flare fittings for the radiator, just bubble flares on the those ends). It was either find some of those for a short run of silicon hose (as Inline Tube suggested), or cut off & flare the ends after chasing down some flare nuts – either way, it was a trip to a local parts store.BTW – I now have 2 complete sets of 304 block Freeze Plugs if anybody needs a set. LOL!


Day Two

Got the condenser and radiator mounted, and rewired the H4 Relay Kit to pop out the driver side (to leave room for the A/C hoses). Meanwhile, Dave got the alternator and A/C compressor mounted up. The Nostalgic AC instructions leave a bit to be desired (compared to the Classic Auto Air system I put in the Mach 1, so it was a bit of a slog). Also made a custom bracket for the dryer, since the fenders open up – the dryer needs to stay put, so it’ll live where it’s supposed to, just not nailed to the inside of the fender. “Swedged” my first A/C hoses today as well, so that was fun. Also drug the Redneck Dual Exhaust out of the overgrown part of the side yard I haven’t been able to get to since the Jeep is jammed up against that side of the carport, so it’s ready to go when it’s time to hang it. Tomorrow, I’m diving under to work on the transmission stuff (shifter cables, cooling lines, etc.) and Dave will probably work on getting the power steering pump back into place – we’ll see.

The front end is done (providing it all works when I plumb and wire everything, that is). Dookie won’t know what to do, as he’s never had a fan shroud since I’ve owned him.
Getting closer – more stuff bolted onto the engine. Dave got the alternator, A/C compressor, and crank pulley back on. It’ll all look better with the new exhaust, valve covers, intake, and the rest of the ‘cleaned up and freshly painted’ parts he took care of yesterday.


JEEP TIME!!!

OK – On Leave… Check. Dave’s Here… Check. The Weather’s AWESOME… Check. It’s JEEP TIME! It might sound trivial, but I got the new headlights installed today, and it turned into an “All Day Sucker” project. It’s all about doing things in order so I don’t have to go back and take something apart to do something I missed, then do the other thing(s) all over again. First things first: headlights… then, the A/C condenser, then the radiator, and finally the fan and fan shroud. Once those are in-place, I won’t have to take them off again to do all the wiring for the headlights. Oh did I forget to mention I’m going with LED Halos and an H4 relay kit? (Had to wire all that up and make it nice).Dave was busy meticulously cleaning all of the engine bracketry, power steering pump, clutch fan, and got ’em all painted as well. Seems oddly fitting, since it all came off of HIS Jeep’s engine. LOL!!

“With One Headlight!” Dang, I liked that song. Here’s one of the new LED Halo H4 lights installed, compared to the old halogen style stock headlight. The old lights were Omega from a VW bus that had H4 bulbs, actually. The H4 relay kit should make things a LOT brighter, though.
Got ’em both in, now just gotta sort out the black spaghetti in front of the grille – that’s the H4 Relay Kit waiting to go in.
OK – we’re buttoned up for the night. Got the headlights, H4 Relay Kit, and LED Halo ballast resistors installed. Had to modify the factory headlight buckets, since the notches for headlamp alignment didn’t quite match the new [plastic] lights from Oracle.


Made me a Fuel Sump Bracket

Just built a bracket to mount the Edelbrock EFI fuel sump to the firewall. There’s a pinch-weld seam right where I wanted to mount it under the battery tray, so rather than destroy that, I made a ‘spacer’ mount for the sump unit. Turned out OK, it’ll look better once I paint it and mount it all up, and I can’t help thinking about how much nicer it might’ve turned out if I only had a real shop with some actual metal working tools to use (like a brake, big bench vise, etc.). Oh well – it’ll work. Also got the new hatch struts installed. No pics, but if you’ve ever seen a Jeep hatchback open and not falling down, you’ve seen ’em all.

Here’s another piece of the same sheet of perforated sheet metal I used on my rack-mount server fan bulkhead last year. Just 3.75 sheets of the stuff left. LOL!
Fits like a glove. Works like a champ. (Insert victorious old adage here).
It’s not really bent that badly – cell phone camera pic. It’ll look better when it’s painted and mounted up for real.