My Project

[zukirider21]

Hey guys. I finally picked up a parts truck and I should be getting the ball rolling with this huge project this weekend. I have a bunch of random questions (some probably have already been answered, forgive me, i just wanna have everything in the same place), and I'm sure I'll have a million more, so instead of making a bunch of threads and cluttering up the forum, I'll just post everything here.

At the moment, here's a few things I would like to know:

1- My parts truck is a 1991 2.9L 5spd 4x4 XLT Ranger. It has a REAL dana 35 with REAL dana 35 guts in it, right?

2- Im going to wire the NSS and clutch switch always closed. This wont effect anything other than the starter and 4x4 engagement, right? (I know, never do that, ra ra ra. Well, I'm doing it as long as there arent any ill effects).

3- My 4x4 conversion involves using the factory pushbutton system next to the heater vent. I noticed my 2wd truck is already wired for it with a plug just chillin in the dash behind the dummy vent. Where is the plug thats supposed to connect to the TC?

4- What is involved in converting a 2wd M5OD-R1 to a 4x4 one? I have a bad 4x4 one with no 5th or reverse, and a good 2wd one.

Those are a few questions to start with, I'm sure I'll have more. Thanks alot in advance

 

[zukirider21]

a few more questions-

are the VSS/speedo gears the same between auto and manual trucks?

do i need to swap computers when i convert from 2wd/auto to 4wd/manual?

are there ANY wiring harness differences between a 1991 4wd/5spd and an 1989 2wd/auto? both 2.9L

are the shock towers different between 2wd and 4wd?

 

[trail B2]

1a.I got a 90 2.9 with real one I read on here somewhere hybrids on 4 cyl
2a.I bypassed my clutch I like living on the wild side.
3a.I have a manual TC but I know there is another component behind your seat
4a.You need to change the tail shaft and the tail end housing.Unfortunately by the time you get the tail shaft out the only thing left in the tranny will be the counter shaft.
Swap computers if you can for best results but they run with the auto.
I would think some one else can tell you more but I think the 91 has a maf sensor but not sure.

 

[mhughes165]

where in nj are ya man, if ur close enough i might be able to lend some assistance, ive actually wanted to convert a 2wd truck to 4wd just to say ive done it with stock parts

 

[zukirider21]

1a.I got a 90 2.9 with real one I read on here somewhere hybrids on 4 cyl
2a.I bypassed my clutch I like living on the wild side.
3a.I have a manual TC but I know there is another component behind your seat
4a.You need to change the tail shaft and the tail end housing.Unfortunately by the time you get the tail shaft out the only thing left in the tranny will be the counter shaft.
Swap computers if you can for best results but they run with the auto.
I would think some one else can tell you more but I think the 91 has a maf sensor but not sure.

thanks alot for the input man. i too thought the 91 was gonna be mass air but i cant seem to find a maf so i guess its still sd.

 

[heptofite]

you'll be better off to swap the good parts from the 2wd m5 into the 4x4 m5, rather than try to convert the good m5 into a 4x4 model

 

[zukirider21]

damn well these trannys look pretty simple. anyone know where i can get a nice high resolution exploded diagram of one?

 

[gwaii]

damn well these trannys look pretty simple. anyone know where i can get a nice high resolution exploded diagram of one?

i'll see if i can find a diagram,but i think once you get into it,you won't need one.they are as simple as they look,i can tear one down to the case in about 10 minutes.

 

[zukirider21]

yeah thats what i figured. im pretty good with manual trannys, its those damn automatics that confuse the crap outta me

 

[zukirider21]

got another question- were any of these trucks issued with a spool in the front? when im in 4wd it bucks like crazy on low speed or tight corners. is there anything else that could cause this?

 

[heptofite]

that's not a spool thing, that's a 4 wheel drive thing in general.

 

[zukirider21]

wtf really? ive had many 4wd's before and NEVER experienced this. im not talking about a little shimmey. no, this is pretty violent bucking clearly in the front end. just like my friends spooled bronco.

 

[adsm08]

MAF 2.9s were the 91MY CALIFORNIA EMISSIONS ONLY. Nobody else bothered requiring it.


No factory spool, but a select few were issued with LSD front ends. It's also possible that someone has already been playing in there. You aren't trying this on a hard dry surface are you?

1 7029 Thrust washer
2 7025 Input shaft bearing and cup
3 7017 Input shaft
4 7120 Input shaft needle bearing
5 7030 Snap ring
6 7N112 Spacer
7 7107 Synchronizer ring, third/fourth gear
8 7124 Synchronizer assembly, third/fourth gear
9 7107 Synchronizer ring, third/fourth gear
10 7101 Mainshaft, third gear
11 7127 Needle bearing, third gear
12 7061 Output shaft
13 7133 Needle bearing, second gear
14 7102 Mainshaft, second gear
15 7107 Synchronizer ring, second/first gear
16 7124 Synchronizer assembly, second/first gear
17 7107 Synchronizer ring, second/first gear
18 7133 Needle bearing, first gear
19 7100 Mainshaft, first gear
20 7069 Sleeve
21 7118 Roller bearing
22 7112 Countershaft cluster gear
23 7072 Washer
24 7142 Output shaft, reverse gear
25 7R205 Output shaft, rear roller bearing
26 7B364 Locking nut, output shaft rear bearing
27 7G450 Pick-up wheel
28 7C434 Spacer
29 7065 Countershaft front roller bearing
30 7113 Countershaft
31 7121 Countershaft roller bearing
32 7173 Sleeve
33 7R130 Countershaft cluster gear needle bearing
34 7158 Countershaft cluster gear needle bearing
35 7107 Synchronizer ring, fifth/reverse gear
36 7124 Synchronizer assembly, fifth/reverse gear
37 7107 Synchronizer ring, fifth/reverse gear
38 7R482 Thrust washer (two-piece)
39 7C340 Thrust washer
40 7N040 Countershaft reverse gear
41 7N270 Countershaft reverse gear needle bearing
42 7N270 Countershaft reverse gear needle bearing
43 7L324 Thrust washer, countershaft
44 7C096 Countershaft rear roller bearing
45 7N170 Lock nut, countershaft
46 7140 Reverse idler gear shaft
47 7N037 Thrust washer
48 7EB9 Reverse idler gear needle bearing
49 7141 Reverse idler gear
50 7N037 Thrust washer
51 7156 Retaining ring


The first column (1-51) correspond to the numbers in the diagram, the set of numbers and letters in the middle column is a base part number, and the names are obviously the names of the parts.

 

[heptofite]

wtf really? ive had many 4wd's before and NEVER experienced this. im not talking about a little shimmey. no, this is pretty violent bucking clearly in the front end. just like my friends spooled bronco.

i have a b2 with 4x4 and it does the same thing, and it's definately an open front diff.

 

[zukirider21]

it does it on everything, even on loose gravel.

and thanks for the diagram man, just what i needed!