87 XLT - Factory Optioned Restoration

[1qaz]

Finally got to the oil pan...ended up using a chain hoist to raise the engine...it was way too unstable using a jack without the transmission.

Pretty clean on the inside

Total mess on the outside

Here's what's left of the gasket

Bottom end of the motor...wood block above the motor mount as recommended by shop manual...not needed with chain hoist but no way I'm not putting it there after all this

Also, transmission completely tore down

With new parts ready to go in

Transmission should be done in a week or so. Now to the clean up of all these other parts so I can put it all back together.

 

[1qaz]

Ready to go back on...

Exhaust Manifold

Oil Pan

 

[85_Ranger4x4]

Looks really nice.

It is amazing the effort they put into the four cylinder exhaust manifolds. In the same time frame V8's had manifolds that looked like a log with four branches in a row.

 

[XLTsplash]

Looks great !

 

[majorburns]

just got done binge reading this entire resto and im hooked.. fantastic looking truck man

 

[1qaz]

Looks really nice.

It is amazing the effort they put into the four cylinder exhaust manifolds. In the same time frame V8's had manifolds that looked like a log with four branches in a row.

Thank you! Even with the transmission, starter, and catalytic converter out, it was still a little tricky to get out thanks to the EGR tube. That manifold is solid for sure.

Looks great !

Thank you! I appreciate the feedback.

just got done binge reading this entire resto and im hooked.. fantastic looking truck man

Thank you! Still a ton of work ahead...will try my best to keep it informative and interesting.

=============================

More parts ready to go back in:

Transmission was actually in very good shape so no need for the original thought of a remanufacture. Here's the bearings, synchros, and shift forks that came out.

Cost: $750 (Parts = $190; Labor = $560)

Also, tracked down an EGR Tube insulation sleeve.

Cost: $7.50

And a NOS oil pump and pickup tube.

Cost = $51.50 (Oil Pump = $40; Pickup Tube = $11.50)

Still cleaning up, restoring, and sourcing parts in hopes this damn polar vortex lets up in the near future. It's rarely been above 0F since before Christmas.

 

[85_Ranger4x4]

Still cleaning up, restoring, and sourcing parts in hopes this damn polar vortex lets up in the near future. It's rarely been above 0F since before Christmas.

Same here, I don't think my truck ran at all in December, just too cold to mess with. Supposed to get up into the mid 30's tomorrow, I might wake it up.

 

[1qaz]

Same here, I don't think my truck ran at all in December, just too cold to mess with.

Finally got a reprieve from the arctic deep freeze this past weekend. Installed the new oil pump and pickup, pilot bearing, and rear main seal. Then spent 1/2 a day removing 31 years of grease and grime from the bottom half of the engine, cross members, and frame...definitely the worst part of this restoration.

Bought a slide hammer with blind hole bearing puller attachments to get the pilot bearing out...great investment...dirt cheap on eBay

Tried to borrow one from the auto parts stores but none of them had an attachment small enough to fit...used the smallest one which is 10mm - 14mm (3/8 in to 1/2 in)

Around 10 slides and it was out

Rear main seal ready to come out...as instructed in the Ford shop manual...recommends two screws...I only needed the one

Pried right out with the claw end of a hammer

New seal and pilot bearing in place

Oil pump out with new one ready to go in...attached to the engine with two 5/16 inch, 12 point bolts (upper left corner)...took me awhile to find that socket...some debris in the old screen...felt like bits and pieces of the old oil pan gasket.

Great shot from underneath...you can see one of those 5/16 inch, 12 point bolts between the main pump and where the pickup tube attaches to it.

Final view of the mess that caked the front cross member

First two coats of paint on the cross member...those runs on the bottom will disappear with the next coat...took a half a bottle of Zep degreaser, a roll of Scott towels, and more time than I care to repeat to clean and prep...grease and grime was so thick that when it was gone I was down to the bare metal on the cross member.

Currently under a blizzard warning as I type this...hope it warms up a bit this weekend so I can get the oil pan back on and flywheel, clutch disc, and pressure plate reinstalled...pending progress on the frame of course...much easier to work on it with all that stuff out of the way. So looking forward to Spring!

 

[Mark_88]

Looking very good!

When I did my frame it was a complete tear down...motor, cab, box all removed and had a guy shot blast it for me...cost almost $1,000 including doing the bottom of the cab, towing to an fro, welding up my body mounts with huge washers, and blasting my aluminum rims...

Well worth the cost and effort that way though...

Yours looks to be in better shape than mine was...the grunge is actually good sometimes...and if your engine blows oil it keeps the engine bay rust free...lol

 

[1qaz]

Looking very good!

When I did my frame it was a complete tear down...motor, cab, box all removed and had a guy shot blast it for me...cost almost $1,000 including doing the bottom of the cab, towing to an fro, welding up my body mounts with huge washers, and blasting my aluminum rims...

Well worth the cost and effort that way though...

Yours looks to be in better shape than mine was...the grunge is actually good sometimes...and if your engine blows oil it keeps the engine bay rust free...lol

Thanks, Mark! If I had to do it over, I'd take the plunge and strip it down to the frame. But I have been able to enjoy her along the way...

============================

Oil pan finally back on!

Fan and shroud ready to go back on...

Rear cover plate clean...there's a little Millennium Falcon in all of us.

Meanwhile away from the engine...wheels remanufactured.

Before

After

She turns 31 tomorrow.

 

[85_Ranger4x4]

Did she get any more presents for her birthday?

 

[1qaz]

Did she get any more presents for her birthday?

U joints!

She can use some new ones.

 

[1qaz]

I wish I could update this thread without bumping it to the top.

After several months, the transmission is finally ready to be reinstalled. A lot of work went into it and it seems fitting to share it. I'll start with the obligatory 'After' pic.

The infamous top two bolts...I got to them from the top of the engine bay with a 1/4" ratchet.

The 'Before' pics.

Completely disassembled at a local shop who gave me access, let me chase my own parts, and let me learn...a ton!

New parts that went in (pic posted previously).

Old parts that came out (also previously posted)

And here's how it looked coming out of the shop (also previously posted)

Finishing restoration touches...

Bell housing cleaned and prepped...

Transmission prepped...

After a few coats of Eastwood's AlumaBlast...

Back together and ready for installation...

Part number for a 1987 Toyo Kogyo 5-speed manual transmission bell housing...

And, finally, the 'serial' number stamped on the transmission...

Ready to go back in once the weather thaws. So ready for Spring!

 

[1qaz]

More parts coming out for cleaning...air cleaner and intake and right front wheel well liner.

Wheel well liner cleaned...

And restored...

Will go back in when I finish the frame rail. Corroseal'd it today to kill any of the surface rust. Here's what it looks like when first applied.

And as it dries.

Any rust is turned to black primer. It's ready to paint when the weather permits.

 

[black06xlt]

looks good... what are some future plans