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

 

[Curious Hound]

That should keep you busy for a few munutes.

By the way. "Rear main seal" is rear crankshaft seal. So, when you say "crankshaft seal", are you being redundant or referring to the front crankshaft seal?

 

[Li'l Work Truck]

That should keep you busy for a few munutes.

By the way. "Rear main seal" is rear crankshaft seal. So, when you say "crankshaft seal", are you being redundant or referring to the front crankshaft seal?

I was referring to the front crankshaft seal. I always just knew them as "rear main" and "crankshaft" seals. I suppose it makes sense to call it what it is.

 

[Rick W]

That should keep you busy for a few munutes.

By the way. "Rear main seal" is rear crankshaft seal. So, when you say "crankshaft seal", are you being redundant or referring to the front crankshaft seal?

That write up is fantastic! I think if I started with that kind of inspection and detail when I started on mine, they would’ve never been done. Mine was more “fly by the seat of your pants,“ except, with my health issues, it was more like “drag your ass on the ground“ as it went down. And it’s still ongoing.

Thank you for the reference for motivating you! Now, in keeping with the bond of friendship in this group, let me whip on you because “no good deed should go unpunished!”

Pictures! Pictures! Pictures! I, and we all, live for the pictures on this site.

I already learned something. I didn’t realize any Ranger ever had a six speed transmission.

Good luck with it all!

 

[Li'l Work Truck]

Pictures! Pictures! Pictures! I, and we all, live for the pictures on this site.

I already learned something. I didn’t realize any Ranger ever had a six speed transmission.

Good luck with it all!

Maybe in my ignorance I refer to reverse as its own gear? I figured, 5 forward, one reverse. And trust me, there will be pictures! I'll do a couple shots of the Before situation today just for you, @Rick W ! Hmm... Might have to set up my camera and do a quick and dirty uncut video, too.

Parts list inbound!

 

[lil_Blue_Ford]

Sounds like what I consider a “full overhaul” on a vehicle, lol.

It will be pretty darn close to a “new” truck by the time you work through that list. The good news is that it should be relatively trouble-free for 5-10 years after all that work.

 

[lil_Blue_Ford]

Maybe in my ignorance I refer to reverse as its own gear? I figured, 5 forward, one reverse. And trust me, there will be pictures! I'll do a couple shots of the Before situation today just for you, @Rick W ! Hmm... Might have to set up my camera and do a quick and dirty uncut video, too.

Parts list inbound!

You only count forward gears when referring to a transmission or you can list it as a 5-speed, one reverse. Smaller vehicles don’t typically have more than one reverse gear though, that’s more of a big truck thing.

 

[Li'l Work Truck]

You only count forward gears when referring to a transmission or you can list it as a 5-speed, one reverse. Smaller vehicles don’t typically have more than one reverse gear though, that’s more of a big truck thing.

I listed it as a 5-speed manual. I suppose I could've said 'every gear" to avoid confusion.

 

[scotts90ranger]

What do you mean it "shears" in all gears? at 160k that thing shouldn't be all that bad, my '90 is fairly sloppy even after two overhauls but I actually prefer how it shifts compared to my '97 that's still pretty notchy and crisp somehow at 245k... it's making noises though, I'll try a fluid change sometime in the next month hopefully...

 

[Li'l Work Truck]

What do you mean it "shears" in all gears?

If the transmission is in neutral, no noise is made. If you put it into any gear you get a similar noise to worn out pads dragging on old rotors. The pitch and intensity is unique to each gear, and when I replaced the transmission fluid to check for issues, the magnetic drain plug came out looking like a cactus. Several large shavings surrounded in a bright red coat of some very thick transmission fluid verified my concern that the transmission is prematurely worn.

I chose the word "shear" because it is not grinding in the sense that there's no coarseness or hesitation; no need to apply more power to enable movement.