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Starchild

I'm underway so I figured I'd post my progress on this.

A little background:
My passport has undergone several stages of modifications, and once I did the SAS, I never intended it to see much pavement time (The basic specs are in my sig). As they have a habit of doing, circumstances have changed, and I'm in the process of trying to sell my tow rig/DD to free up some cash for a growing family.

My daily commute is all of 2-3 miles, and nothing over 35 mph, so the plan is to make the old passport more street friendly and use it as a DD for the time being. This is one way I can justify keeping it around.

Against my will, I've recently put about 200 highway miles on the rig, so I know what areas need some attention. Here is my list of items to address in order of inportance:

-replace welded rear with open diff
-new rear driveshaft (current one is heavy and unbalanced)
-fix exhaust rattle
-build rear t-case mount
-fix speedometer
-install line locks (makeshift e-brake)
-replace AC compressor
-smaller more street friendly tires

I've put the tires at the bottom of the list because of price, but if I find a decent set of used 35's, I'll jump on them.

Here is my new DD Cool

This past week, I've been working on replacing the rear diff. I welded up my spider gears, so I picked up an old set for free from a friend. I failed to take pictures, but the corporate 14-bolt is a interesting axle to work on. It's a full floater, which means you can pull the axle shafts without removing the tires. One was a bit stubborn, so I had to weld a nut onto the flange since there is nothing else to grab onto, and use a slide hammer to get it out. Everything about this axle is heavy. The carrier with ring gear has to weigh 60lbs easy! The carrier is two pieces, so once you unbolt the ring gear, it splits in half, which makes replacing the spider gears simple. I just need to seal the axle back up before I move onto the driveshaft.

I've got some stock driveshaft parts that I will be combining with new parts to build a one piece shaft. It will use an Isuzu D44 flange up top, and I need to get a new 1410 yoke for the back to match up with the 14-bolt. I can only find half of a stock slip yoke, so I'll have to see if a new one is cheaper/easier than going to pull one from a yard. Going to have it professionally built and balanced. The one I'm running was re-tubed by a friend after I pretzeled it playing on some rocks. He used something like 3/8" wall drill pipe so I wouldn't have that problem again, but at any speed, it wants to shake the truck apart.

I'll keep this updated with my progress. I've gotten a couple promising calls about my Chevy today, so I need to get my butt in gear on this.

Andre
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1994 Trooper - Delightfully close to stock

bigpoppax2 · Posted: Tue Nov 10, 2009 7:21 pm Post subject:

I think you will be glad you went this route.

I'm glad to hear you are making progress. The drive shaft will make a huge difference in getting it DD ready, the welded rear was probably no fun either.

Joe
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After concealed carry guy shot a gun wielding robber....."I'm just a Law abiding citizen dumping some chlorine into the gene pool"

98 RodeoPort 34" LTB's, Supercharged and some other cool stuff.

bigpoppax2 · Posted: Tue Nov 10, 2009 7:23 pm Post subject:

http://jacksonville.craigslist.org/pts/1457891499.html

http://jacksonville.craigslist.org/pts/1456035115.html

Here is the best deal: 4 Pro Comp Xterrains for $175
http://jacksonville.craigslist.org/pts/1426529740.html

Look look!!!

Joe
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After concealed carry guy shot a gun wielding robber....."I'm just a Law abiding citizen dumping some chlorine into the gene pool"

98 RodeoPort 34" LTB's, Supercharged and some other cool stuff.

DAMUDKING · Posted: Tue Nov 10, 2009 9:06 pm Post subject:

just trade me rodeo's, much less work....and just because i like you ill through in a 3.4 and a set of new tsl's Very Happy

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92 V6 RODEO, 12 bolt rear, LSD, 4.56's, 4.5" lift, 33x13.5 LTB's

maxwell417 · Old Timer Joined: 27 Nov 2003 Posts: 1199 Location: Kansas

My daily drive is 30 miles, max speed of 65. With welded rear diff and 35s it is a pretty comfortable ride. Only times I wish for a locker or open is parking lots. If I only had to go 2-3 miles, I wouldn't bother at all. I have a balanced cv type rear driveshaft, getting driveshaft vibes gone made me very happy.
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Curt B. Isuzu Troopers 89RS Delta Cam, Calmini Header, 33s & '90 3.4v6, SAS D44 ARB /Horbart 5.38s 35s my pictures

Starchild · Posted: Tue Nov 10, 2009 11:40 pm Post subject:

Ditchdoc · Posted: Wed Nov 11, 2009 7:17 am Post subject:

Hummmmm

Man I really like your port.... I might have a Trooper or two that I'd trade ya if you really wanted a DD....... Wink

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Peter
My Cardomain Page ; Tread Lightly ; SFWDA ; The BlueRibbon Coalition ; Equal Tire Balancer

92 Trooper LS 3.2L DOHC, AT, Stock, 185K, Blown head(s) and bad water pump??
94 Trooper LS 3.2L DOHC, AT, Stock, 132k Future ECORS Class B race rig
94 Trooper LS Parts Trooper
85 VW Vanagon Family Hauler (For Sale)
88 Ford F250 Extended Cab Long Bed, 460, 4X4, New Tow Rig, AKA: The Beast Twisted Evil

Bansil

Fixed it for you
headbang

marshall · Posted: Wed Nov 11, 2009 10:04 pm Post subject:

What size rims do you have? I'm about 1/2 way through my SAS and would like some 38" tires, the 35's look small.

Starchild · Posted: Thu Nov 12, 2009 3:30 pm Post subject:

Thanks for the commentary Doug Laughing

I never said all those items were necessary. Hell, I'll be happy with a balanced driveshaft and no leaks Wink

Marshall, my wheels are 16x8. I'm actually going to be in Tallahassee this weekend.

Andre
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1994 Trooper - Delightfully close to stock

younggun · Found The Light Joined: 25 Mar 2008 Posts: 274

it just looks weird seeing another marshall.
there arent many marshall's around.

Smiley · Posted: Sun Nov 15, 2009 8:31 am Post subject:

Progress report?

I guess I just need to see some photos (or perhaps even a scant few words) depicting a real-live, running/driving, White 1st Gen Rodeo/Passport......... for encouragement's sake, you understand.

Cheers!
Smiley
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“I don’t know what you’re painting that drive shaft for… it’s not like anyone’s ever gonna see it” ~ Joe Berry (circa 2004)

Bansil · Posted: Mon Nov 16, 2009 7:46 am Post subject:

Starchild · Posted: Mon Nov 16, 2009 9:47 am Post subject:

I was out of town this weekend, so no progress. I need to get down to the pick and pull for a drive shaft to retube.
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1994 Trooper - Delightfully close to stock

Starchild · Posted: Mon Nov 30, 2009 9:52 am Post subject:

Sold the Chevy on Friday! Got a pretty decent price for it. Glad that's done with.

I got some work done on the Passport over the holiday as well. I was sealing up the axle shafts, and I couldn't find my torque wrench (I think it actually broke), so I was torquing the bolts with a breaker bar. The first side went fine, but I guess my arm isn't calibrated for a 2' breaker bar, because I ended up stripping out half the bolts on the passenger side hub Mad

Fortunately, when I bought my axles, the guy threw in two sets of spare axle shafts and a set of hubs. I grabbed one from the shed, and had it swapped in less than an hour.

I also got some pieces cut for the rear T-case mount. The battery is charged, so I should be rolling this week.

I also started perusing craigs list for a possible cheap DD. I found a 95 Rodeo 4x4, 5-speed locally for $400. The guy probably needs a timing belt (probably tensioner, 168k), and a clutch. I mentioned this one to the wife, and she said it sounded for a piece of junk for that price, and that she was thinking more along the lines of $2-3k for a more reliable vehicle.

Since I always listen to my wife, I started looking in that range, and came up with an '01 Rodeo 4x4, 5-speed with 122k for $2500. I'm going to call about that one today.
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1994 Trooper - Delightfully close to stock

Bansil · Posted: Mon Nov 30, 2009 11:05 am Post subject:

Ditchdoc · Posted: Mon Nov 30, 2009 11:09 am Post subject:

Tad · Posted: Mon Nov 30, 2009 12:47 pm Post subject:

Great news. Have you made progress on the t-case to trans leak problem?

-Tad
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tad@planetisuzoo.com
http://www.planetisuzoo.com
2001 Trooper - 4.77s, 3xARB, OME 919HD springs. 255x85 Maxxis Bighorn MTs
1999 Rodeo - rebuilt DD
1980 300GD
2000 Suburban
2000 E320

Starchild · Posted: Mon Nov 30, 2009 12:51 pm Post subject:

Not really. I think the leakage comes from the bolts constantly backing out. I decided to work on the rear mount, which will connect the back of the T-case to the skid plate/cross member before I pull that off to tighten up the connection. That way I can do the final welding and paint while it's off.
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1994 Trooper - Delightfully close to stock

Starchild · Posted: Mon Nov 30, 2009 1:01 pm Post subject:

Ditchdoc · Posted: Mon Nov 30, 2009 5:58 pm Post subject:

Starchild · Posted: Mon Dec 28, 2009 10:40 pm Post subject:

I've finally been getting some time to work on the truck over the holidays. Here's what I've been working on.

rear t-case mount

here is how it mounts

I'll get a pic of it mounted to the skid plate in the morning.

My cable shifter vibrated apart and lost several parts. This is one of the two stand-off's. It's a 12" piece of 3/8" all thread sleeved with tube to mount the cable ends.

I also lost one of the rod ends. The one on the right is the replacement.

Here it is mounted up

I have everything painted, installed and sealed. Just need to fill the t-case in the morning and take it for a drive. Depending on how it goes, I may be getting a new driveshaft this week.
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1994 Trooper - Delightfully close to stock

Bansil · Posted: Tue Dec 29, 2009 7:26 am Post subject:

cool,and congrates on the calender pic,that was a fun day in the rocks Wink

How in the H--- did you "lose" a heim end?? it's threaded on the end and had a bolt in it???

Washing machines vibrate as much as those boggers and they don't "lose" bolts thefinger

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http://www.cardomain.com/ride/505863

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http://forum.planetisuzoo.com/viewtopic.php?t=18800&highlight=lowrider

Smiley · Posted: Tue Dec 29, 2009 9:45 am Post subject:

Starchild · Posted: Tue Dec 29, 2009 9:48 am Post subject:

You know how when you get a badly unbalanced load in the spin cycle, that thing wants to walk across the floor? I thin it was like that Laughing

What calender?

Andre
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1994 Trooper - Delightfully close to stock