1994 ExCab 4.0 "Grimace"

[eaglescout94]

I'm still figuring out what parts I want to use and putting together a plan of attack. The overall plan is to build this truck to be able to daily drive it and also have it for use on hunting trails/ easy offroad during season. I've got new clutch components on their way to swap in a 5 speed from another truck, trying to get prices on and figure out what rear springs I want and subsequently how much the front will need to come up. Ive cut about 10" off the flatbed and have a utility shell I'll build a base to be able to mount to the flatbed during winter. Gonna rock the mud tires for a bit but might just get a new set. I'm calling it Grimace since its a wonderful purple, decided to build it over using for parts since its my age down to the month.

 

[Bgunner]

Ahh Yes, the good old paint code "GA". I love this color and have one myself. Technically it is a maroon but it has so much blue in it that depending on the light it is purple.

 

[SenorNoob]

Looks like a nice start to a project. What are the bed sides? Is that wood?

 

[eaglescout94]

Yep, wood. Built to go in the stake pockets. I’ll build a new set once I have the bed finished up that are a little taller probably. They’re fairly worn but atleast they used stainless hardware

 

[scotts90ranger]

I think a set of explorer leaves would put you in a good spot, at this point they're all old and worn out so probably better off going new, I'm not sure there's any difference between the heaviest ranger leaves and the heavy Explorer leaves other than the center bolt being flipped on the explorer leaves (they're spring under), either way should be close... not sure if it would be tall enough to get rid of the blocks unless you used the chevy lowering shackles as well...

If you want to space the front up a bit either going to new springs (I think first gen Explorer coils are a bit taller but might be the same as super cab springs) or get some 1 1/4" washers to space the bottom of the coil up... I say 1 1/4" washers since they have the 1 3/8" hole you need to fit around the hex, 1 3/8" washers are exponentially more expensive and have a 1 5/8" hole... it's like lumber math, don't ask, I don't know...

 

[eaglescout94]

I knew the explorer leaves were and option but for some reason haven’t looked into them yet. I’m waiting to hear back at the moment from a local spring shop on what they’d charge. I planned on getting the Chevy shackle and could either use it and delete the block or if I wanted more height I could use it and still keep the block. Either way my rear springs are junk, pretty much dead flat and broke on the passenger pack. I can lift the rear corner of the truck a couple inches before it gets heavy.

Thanks for the tip on the washers. I’ve seen some of the puck type spacers and leveling coils but washers sounds a lot better so long as my springs are in decent shape.

 

[eaglescout94]

No new pics or actual progress other than I got the truck in the garage last night. My clutch, flywheel, and hydraulics arrived today, pedals and bearings should be here tomorrow.

Local spring shop was higher than online for a set of springs. I placed the order for a set of HD ranger springs, gonna get my eye bolts this week, hopefully get everything else I need at the house so I can start taking the truck apart and putting good new bits in it. Front tires look like they're leaning in a little but I'll measure ride height just to see how its sitting then make a plan after the rear is all together.

 

[eaglescout94]

I think I have all my main parts to do the swap, trying to figure out the wiring aspect has me slowed down though. Some threads say one thing and others say another. I have the mostly complete 95 to use for some parts that will transfer over hopefully, I hope to have the auto and electric transfer case pulled from the 94 by the end of the month as well as the manual trans and case pulled out of the 95 in the same time span. I need to pick up a torque bit so I can remove the seat belt mounts on the floor to get the carpet out and ready for the other cleaned carpet I have.

Hopefully I can get some progress pics of actual progress getting done, Ive got the rear springs in and can see a definite need to bring the front up some. As well as remove the fenders on the flatbed and make it a true flatbed.

 

[eaglescout94]

Got the donor transmission and case removed. Grimace is in the air so I can fit underneath easily, I’m too used to working on my super duty or larger. The new pup supervised the work today since it was so nice out

 

[eaglescout94]

Drained the automatic transmission before pull it, should have it out this evening taking my time on it. After seeing inside the pan I’d say doing the manual swap was the smarter move for sure. With any luck I can drive it out of the garage within the next week. Then it’s off to a car wash with a bag of quarters and plenty of degreaser. Lower engine is nasty looking and the rest of the truck is covered in dried mud.

 

[SenorNoob]

You're supposed to clean it BEFORE you work on it... Makes it so much easier.

 

[eaglescout94]

I tried. It wasn’t easy getting the truck and trailer into the car wash. And so much dirt under the bed, I cut the rear off and I have better access to it all.

 

[rumblecloud]

Thanks for the tip on the washers. I’ve seen some of the puck type spacers and leveling coils but washers sounds a lot better so long as my springs are in decent shape.

These are the washers I used. Spot welded them on three sides (the black marker). About 1-1/2" lift for leveling only.

Adjustable bushing for DIY alignment from Amazon.

 

[eaglescout94]

Ended up ordering leveling springs, if I remember correctly mine are past the measured height anyways. Still can fine tune height with washers though. I’ll have to track down some adjusters to have on hand. On e ride height is settled I’ll get it aligned before spending on some new tires. TIL then the mud terrains on it should be ok

Got the busted auto out after fighting it way too much. could have saved myself some trouble if Id undone the torque converter from the start. But now ive got it out, the flywheel and spacer plate out. I tapped in the freeze plugs on the manual trans to hopefully avoid any leakage and issues from it. Hoping to get teh new flywheel with bearing and the clutch installed tomorrow night. With any luck ill have th trans in and the truck back on its wheels by the end of the week, maybe even driving out of the garage.

 

[eaglescout94]

Making slow forward progress, working after work in the evenings for a bit here and there. Ive got the transmission and transfer case in the truck finally.
As a bit of advice for someone doing a manual swap, yes, it's possible to remove and install a transmission with the exhaust in place but man does it suck. Also, be sure to check for the alignment dowels before the transmission is only inches from bolting up, its not fun removing some with everything there.
I'm really hoping to drive out of the garage by the middle of the month just picking away at it. I lucked out and a friend found a tilt manual column in a yard near him.