The Saga of Truck Norris

[Li'l Work Truck]

@Rick W asked me why I hadn't started a build thread. Originally, I figured this was just maintenance, but looking at my home gym turned Rock Auto receiving dock, the multiple auxiliary lighting systems, OEM+ stereo build, and probably a plethora of other things I plan to do, I might as well start one here. The name Truck Norris was given to my Ranger by my wife, who says its full name is Truck Norris, Texas Ford Ranger. Why not? Below is a rundown of tthe truck, the status, etc. I know a few people already know this.

Truck Norris, 2008 regular cab, 6' bed.

Drivetrain:

• 2.3L (171,000 miles)
• 5-spd, 2WD, 3.73 open diff

Suspension:

• Coil spring front suspension
• HD uprated springs per VIN

Goodies:

• Vinyl 60/40 split seat
• Rubber floor
• Manual windows - not a Windows manual. That's something else entirely
• Bed box
• Cheapie but cool-looking brush guard
• Bedlinerish
• Tinted windows
• 15x8" Ultra mod wheel
• Trailer hitch

And that's where that stops. I got ripped the off. New to Rangers, didn't know to look in specific places for things other than what I found in a few searches, so I didn't know that:

• The suspension is done. All the bushings are shot. It's not just old, but dangerously out of alignment, with most of the alignment plates missing, because until a few days ago, I didn't know what alignment plates were. The truck drives fine until you get to 55-60, and because I have no other choice but to drive it, I keep it under 60 and only drive it when I have to.
• The light for the driver's side airbag will just stick around sometimes (recall fixed, will warranty claim). Figured that's why he left a picture of his girlfriend tucked in the cluster just so.
• The transmission shears in all 6 gears.
• The engine was cleaned to remove any oils. Found out the rear main and crank leak, and the valve cover gasket leaks.
• The steering rack is shot.
• The clutch master leaks.
• Belt squeal after a month in requires troubleshooting.
• Truck has a small coolant leak.
• The 3/4 spare is off of some front wheel drive car. Not sure if the center bore even matches the truck's.

I'm a FWD guy. Most of my experience has been with Festiva/Aspire, Fiesta ST, Fiat 500 Abarth, and MINI Cooper S, so I knew I was stepping into relatively unknown territory. I didn't know that I was going to get a crash course in truck repair, but here I am.

So! Here's the list of things to address...

• Suspension
  • Front coils
  • Front upper & lower control arms
  • Front bushings
  • Front shocks
  • Front LCA to sway bar links
  • Camber bolts
  • Rear springs
  • Rear shocks
• Steering
  • Steering rack
  • Steering pump & hoses
• Engine
  • Valve cover gasket
  • PCV replace
  • Oil catch can
  • Crankshaft seal
  • Timing chain
  • Coolant pump
  • Upper and lower rad hoses
  • Rear main seal
  • Engine mounts
• Transmission
  • Rebuild transmission
  • Replace clutch (stg 1? )
  • Rebuild rear axle?
  • Upgrade from open diff?
  • Transmission mount
• Body
  • PDR
  • Remove & reapply bedliner
  • Minor touch-ups
• Cab
  • Update to LED lighting
  • Add under-dash accent lights
  • Fix/swap seats
  • Install stereo
  • Install sound mat
  • Customize bezel
  • Install GMRS radio
  • Install Sickspeed shift knob
• Lighting
  • LED indicator upgrade
  • Digital flasher upgrade
  • Add under-hood service lights
  • Truck box light
  • Trailer hitch light
  • KC Daylighters for brush guard
• Misc.
  • Replace spare
  • Line bed box w/carpet
  • Detail, paint correction, ceramic coat, polish wheels & box
  • Debadge tailgate, install new RANGER sticker.
  • Tires
  • Alignment