Jballard81's 1994 super cab 4.0 4x4 Restore

[jballard81]

Finally worked up the effort to attempt a more permanent fix on the throttle body end of my intake tube.

Before:

I cut the TB end off of a 2000 4.0 intake tube. However, I didn't measure very well bc it didn't slip over the old intake how I was hoping.

So I got a 3.25" to 2.5" turbo coupler off Amazon for $10. Used some slow set super glue to glue them into place, then followed up with the JB plastic weld

Will cover the plastic weld with some flex spray for some extra protection tomorrow. It doesn't look as bad as the aluminum tape at least!

I think if I had cut a little further up on the donor tube it would have been able to slip on like I wanted it to in the first place.

 

[NakedDucks]

I told you that Flexseal is the way to go!

 

[jballard81]

I told you that Flexseal is the way to go!

First time working with flexseal. I wish i had worn gloves. the stuff gets everywhere! glad i went overkill on the trashbag spray area and it's just all over my hands lol.

i shoved a shop towel into the inside of the broken part of the air box side. it only has one bad crack and with the shop towel on the inside of the crack I hope that the flexseal will form just on the outside... guess we'll see!

 

[MT_PLS]

Have you thought about reaching out to someone locally and having them scan the part and then 3d printing a new one?

 

[jballard81]

Have you thought about reaching out to someone locally and having them scan the part and then 3d printing a new one?

you know, that really is a great idea! actually, i've been meaning to look into a 3D scanner so maybe it's something i can figure out... Do you have any experience with 3D scanning?

 

[MT_PLS]

you know, that really is a great idea! actually, i've been meaning to look into a 3D scanner so maybe it's something i can figure out... Do you have any experience with 3D scanning?

I have a couple of friends who have 3d printers, when they need something scanned they typically go to the local community college.

 

[MT_PLS]

https://digitalmakerspace.uncw.edu/

 

[jballard81]

https://digitalmakerspace.uncw.edu/

appreciate it. a quick google search revealed that some of the later model iphones have lidar sensors with their cameras and are actually passable 3d scanners. not great, but not bad. anything else is pretty much useless until you get into a professional scanner type thing (which has lidar i believe as well)

thanks for the link!

 

[MT_PLS]

It would probably be worth checking for maker spaces local to you to see if they have the 3d scanning and printing capabilities.

 

[Terrys87]

Just getting caught up on yourthread. The hub cover looks great. I too am going to have to just remove the faded aluminum and paint as close to color as possible. Seen you ahve been doing some interior work. Head liner is a bigger job then you might think but just takes time and patience. Good luck chaisng drivetrain vibration, those can be difficult.

I found a couple of yards that have quite a few ranges. I will look for a 94 3.0 air intake tube.The 2nd gen Rangers are fairly easy to find here. Will probably be a couple of weeks before I get out there as I switch shifts for a week and rain here for a while.

 

[el_duderino]

Any chance you figured out what was causing the shudder? I'm having the same issue and I am hesitant to throw a new torque converter on or not.
Keep up the great work! Its looking good!

 

[jballard81]

Any chance you figured out what was causing the shudder? I'm having the same issue and I am hesitant to throw a new torque converter on or not.
Keep up the great work! Its looking good!

Still fighting the good fight. If you're replying to my thread, i'm guessing you've seen all the things i've tried to fix it so far. At this point, i have a set of reman fuel injectors to install to see if maybe one (or more) is weak or partially clogged causing intermittent misses which just happens to be really noticeable at the 2k rpm range.

if not that, I've either missed something that i've deemed 'repaired' or maybe an issue with the torque converter. The transmission itself is shifting clean and as smoothly as an A4LD can, so I don't believe that's the issue at this point.

 

[jballard81]

Temperature warmed up so it's nice enough to work in the garage. Figured now was the right time to replace the fuel injectors.

Broke about half the clips on the injector plugs and then removing the fuel rail and injectors was tougher than I thought it would be. The two on the front passenger side remained in the engine once the fuel rail finally pulled free.

Twisted them out with pliers, they're pretty chewy. Bunch of nastiness right where they go into the engine that I had to vacuum up.

They all looked pretty rough but the injector end was pretty clean except for one which looked at least partially clogged

Fuel pressure regulator looked rough so I ordered one from Amazon. Parts store wanted more than $100 for one...

Hopefully can get it back together tomorrow!

 

[sgtsandman]

Temperature warmed up so it's nice enough to work in the garage. Figured now was the right time to replace the fuel injectors.

Broke about half the clips on the injector plugs and then removing the fuel rail and injectors was tougher than I thought it would be. The two on the front passenger side remained in the engine once the fuel rail finally pulled free.
View attachment 123023

Twisted them out with pliers, they're pretty chewy. Bunch of nastiness right where they go into the engine that I had to vacuum up.View attachment 123024

They all looked pretty rough but the injector end was pretty clean except for one which looked at least partially clogged
View attachment 123025

Fuel pressure regulator looked rough so I ordered one from Amazon. Parts store wanted more than $100 for one...

Hopefully can get it back together tomorrow!

 

[jballard81]

Any chance you figured out what was causing the shudder? I'm having the same issue and I am hesitant to throw a new torque converter on or not.
Keep up the great work! Its looking good!

Finally got a chance to drive it after changing the fuel injectors and I 'think' that might have actually fixed my shudder.

My problem RPM range was right around 2k, especially right after transmission shifts. I just did about 15 miles of varied speeds and the engine felt smoother, especially at idle at lights.

I've been burned before thinking it was fixed so I definitely want to drive it a while longer before saying it's good. Also, I got a check engine light

Will have to check that out later...