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'95 Supercab Rehab - Dumb Questions Thread


Did LSD clutches and rear diff fluid, which was almost my last "minor new owner project".

Left-most friction:
95_friction.jpg


Dunno how that happens, dunno where the other ear ended up. I couldn't find it in the diff, and I couldn't find it in the oil pan with the big piece.

Ultimately I think it makes the most sense to pull the 4.56 Explorer rear and D35 chunk from the old truck, regear for this truck using 4.10s I already have, swap this truck's 3.73 axles directly into the old truck and drop back down in tire size, and keep the 4.56s on the shelf since D35 gears can be difficult to get a hold of.
 
Yukon is making the gear sets again…
 
Sort of, right? 4.11 is limited stock, 4.56 is backordered, 4.88+ is NLA.

Last time everything was backordered, it was well beyond their estimated times, IIRC over a year. They're also almost twice as expensive (list price) now as they were before that production gap.
 
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Does anybody have an ID/source for the brake/clutch pedal shaft bushings? I had rolled the dice on Dorman 74016, all of which are way too big.

1000000972.jpg


I see a couple likely candidates, but preferably somewhere that sells them in real life. Although if I can't find my spare brake booster, this is probably going to become a multi-day project regardless.

EDIT: '94 manual says 387957, which crosses to D8TZ-2471-A, which is '94-down, and the shoulder is bigger. Fordpartsgiant doesn't return anything for "similar parts that fit '95". I don't have the '95 body manual. No aftermarket crosses anyway.

EDIT 2: I decided I would get the rest of the '95 manuals when I needed something that was notably different from '94. Happened pretty soon. Unfortunately, the information I was looking for isn't in here:
95_brakes_bushingchange.jpg


'95 no longer breaks the components out of the pedal bracket assembly, so I guess from Ford's perspective you buy a new assembly and that's it. Obviously that's less than helpful.

Amazon has new Chinese pedal assemblies marked '95-'06 under the '06 part number 6L5Z-2455-BB for $45, $30 on sale. The Dorman bushing set was $10-$15, so it's possible the knockoff pedals are the move here.

I cut the black bushings from the Dorman set (medium ID, but thinnest material) down to the first slit in the shoulder to replace my inside two that were trashed, reused the outside two, slathered everything in white lithium grease, and sent it.
 
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Sort of, right? 4.11 is limited stock, 4.56 is backordered, 5.13+ is NLA.

Last time everything was backordered, it was well beyond their estimated times, IIRC over a year. They're also almost twice as expensive (list price) now as they were before that production gap.
Well balls…

I looked like 2 months ago and they had a few hundred sets in stock…

Guess the 4.10 gears are staying in the Choptop for awhile…
 
Well balls…

I looked like 2 months ago and they had a few hundred sets in stock…

Guess the 4.10 gears are staying in the Choptop for awhile…

I'm kinda in the same boat with the torsen LSD for the front axle on the 2011. I'm on the contact list, theroretically, for when they do become available. That was projected to be in May. But crickets so far.
 
Okay, so, new RPM-dependent chirp on cold startup that resolves within minutes at most, not related to the belt drive, doesn't care if the clutch is in. May localize to driver's rear of engine, but it's hard to tell. Actual mileage is unknown.

Oiling? Something external? Or this cam sensor deal that's supposed to explode on 3.0s, not 4.0s, I didn't have on my '94 2.3, and appears to be jammed under the firewall?


EDIT: I've got work, but it looks like my part is '95-specific and rockauto has Dorman, Cardone, and Cardone Reman, so if anyone thinks the noise is that, opinions on whether Cardone new is worth it, what to look for when I pull it out to make sure my cam is okay, and what this "alignment toolkit" is are welcome.
 
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Brakes are working but take increased pedal effort after replacing pretty much everything: cruise master, booster, pads, driver's caliper, and everything in the rear. New booster is confirmed doing something (pedal softens a bit when I start the truck). No improvement after re-bleeding.

What's the culprit here? I bought the most bullshit discount master, but they all have the same bore regardless of 9"/10"/discs in the rear, right?
 
I believe there's an adjustment on the rod on the booster that goes into the master cylinder, it's been so long since I've dealt with it that I don't remember how to do it though...
 
I believe there's an adjustment on the rod on the booster that goes into the master cylinder, it's been so long since I've dealt with it that I don't remember how to do it though...

I’ve had to fiddle with that rod on the town cars. Moving it just a hair can make a big difference, start small and work up. On the town cars, I can pull the master cylinder back far enough that I can adjust it without disconnecting the lines. If you make it a hair too long, the brakes will drag.

For what it’s worth
 
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Thanks guys. Damn, I brought the old booster with me and traded it in directly for the reman, so I couldn't even match the rods. There seems to be a static spec of 0.98" for the length, so it's frustrating it would be wrong out-of-the-box:
95_boosteradjust.jpg

I'll take a stab at it when I have the time.
 
What's the "better" tool (I can buy in real life)/nuclear option on fuel line disconnects?

I've got the generic fuel line/aircon plastic set, 5/16" tool bottomed out, line bottomed out. Pull the line back out and I hear the spring or internal clips or whatever snap back closed, doesn't come off. Borrowed the chrome X tool, won't even go in all the way because it doesn't have a beveled lip.

If the guy who designed these is still alive, I'm going to kick him in the balls.

EDIT: I also hit it with my purse and my wife's purse (20lbs).
 
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What's the "better" tool (I can buy in real life)/nuclear option on fuel line disconnects?

I've got the generic fuel line/aircon plastic set, 5/16" tool bottomed out, line bottomed out. Pull the line back out and I hear the spring or internal clips or whatever snap back closed, doesn't come off. Borrowed the chrome X tool, won't even go in all the way because it doesn't have a beveled lip.

If the guy who designed these is still alive, I'm going to kick him in the balls.

There is a tool set where the tools look like a C that have a lip on the to engage the locking mechanism. I remember seeing them on amazon. I'm not sure who else has them. Summit or Eock Auto might.

They would be real handy to have from time to time but I've yet to buy them. The one line on the 2019, coming off the high pressure pump on the 2019 requires them. The X tool and the few other tools I have won't fit in the small space between the QD and the pump housing.
 
When I did my Explorer I couldn't find any tools handy but had some PEX laying around so I cut off 6", split it in half and trimmed the cut until it was the right diameter to get it done, worked great... I agree, the marine ones are way simpler than the Ford units...
 
My experience is whether it is a cheap tool or an expensive tool, getting the damn things to come loose is actually more a matter of technique. I’ve had the plastic rings with a slot in them, pot metal rings with a slot in them, and even had one that looked like a pair of scissors where half the ring was on one side and half the ring was on the other side. If you can get that one into the location, I liked it because not only could you hold it steady, you could gently tap on the arms of the scissor part to push it in a little deeper, and pop it in better, which pops it loose better. Of course the scissor tools I had, we’re also made out of pot metal, so you couldn’t tap them very hard or they break..

Understand what it is you’re trying to do. In the old days, there was an O-ring and a hard plastic/rubber connector piece that was about the same size as the O-ring, but it had a couple of edges to hold it in place. The O-ring made the seal between the inner tube and outer tube, and that slightly bigger different shaped piece locked the tubes slinky into the kind of double crimped end (think brake line), which kept the two pipes from sliding in and out of each other.

Most of what I’ve seen for the last 30 years, you still have the little green O-ring, but then the other connector part looks like a metal O-ring, but it’s actually a spring that looks like a teeny tiny slinky, connected in a loop.


IMG_5144.png


This was the best picture I could find, but if you look in the lower left of the loop, you can see the coils of the spring.

When you’re sliding the little tool down in the fitting, you are trying to expand that spring ring a whopping 32nd or 64th of an inch to let the O-ring part slide out underneath it. On both the fuel systems and on the AC systems, and in industry we had them on some other things, the whole thing seizes up after a few years. So when you put the tool on there, regardless of the style, you almost have to tap it down gently to get that rubber ring or that spring ring to expand enough, so the O-ring can slide out underneath it.

In my experience, once you get your technique down, 2/3 of them kind of pop off pretty easily. The problem is the other third are kind of frozen in there and you have to get pretty aggressive with them to get that spring or that rubber locker to release. Avoid pliers or vice grips or using enough force that you might actually bend one of the tubes. It’s more a matter of forcefully, wiggling it out, then just pure tension bowling. I’ve to use a pretty good amount of force, (1) pulling on the one pipe and (2) pulling on the other pipe while I’m (3) holding the tool in place and (4) pushing the tool down to release the spring. Each item using a hand.

Hey wait a minute, that would take three or four hands….

Therein lies the problem.

And of course half of them are located in place where you’ve only got an inch or two around the outside of the thing to work.

One last thought, very seriously, no joking, make sure there is no pressure in the system. First, if there’s pressure in the system, that is actually holding that joint together harder than if there’s no pressure, and second, when you do pop it loose, you don’t want a face full of fuel or Freon or whatever
 

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