Big Blue's Transformation

[Steve83]

Gary Lewis wrote

Steve - Did you miss the question about taking the A/C system out as a unit?

Yes, and I didn't see it on that page.

I don't remember doing it when my truck was a bullnose, but I assume it can be done.  Just follow each line (there are only 3) to see if it passes under or through anything that would be difficult to move.

[85lebaront2]

I think with the radiator out and the AC evaporator case either split at the joint or loose the lines go around anything hard that would prevent them from coming up. Hardest part will be having enough hands to keep from crimping a hose, breaking a tube or dropping something (like the compressor).

[85lebaront2]

Gary, I don't remember if it is a strap with one end in a slot, or a complete "surround" style attachment.

[Gary Lewis]

Ok guys, thanks.  I had a church meeting this morning, but I'm headed to the shop soon so will check it out and let you know.

But, Bill has a good point about hands.  I may have to call in help.

[1986F150Six]

Gary Lewis wrote

But, Bill has a good point about hands.  I may have to call in help.

Can you wait until September 21st?

[Gary Lewis]

Actually, August 7th in the PM looks possible.  I think I'm one screw/nut somewhere away from getting the cover off the plenum, which should let everything come out........

Just taking a break for water, a look at the MPC illustration, and to catch up here.

[1986F150Six]

Gary Lewis wrote

Actually, August 7th in the PM looks possible.  I think I'm one screw/nut somewhere away from getting the cover off the plenum, which should let everything come out........

Oh, for a moment there, I thought you wrote that you have a screw loose!

[Gary Lewis]

1986F150Six wrote

Oh, for a moment there, I thought you wrote that you have a screw loose!

Well, what can I say to that?  I have 2 11/4's Bullnose trucks.  I have a little website for them, a forum, host a show/swap meet, and have a document or two.  

[1986F150Six]

And, what do you do in your spare time?

[Gary Lewis]

Spare time?  I spend my spare time in MY workshop, not the devil's.  

Anyway, I'm here to say that the A/C system can come out as a complete system.  Here it is, loose:




And here are the fasteners that need to be removed in order to do that.  Note that the one in the yellow circle actually comes through from inside of the cab.




Once that was out I got a few more things out, inc the radiator support.  And, speaking of that, I'm sure glad I'm replacing it,  The tabs on the bottom of it where the fender liners attach are toast.  The one on the driver's side essentially doesn't exist, and the one on the passenger's side is almost as bad.

[salans7]

Gary Lewis wrote

 The tabs on the bottom of it where the fender liners attach are toast.  The one on the driver's side essentially doesn't exist, and the one on the passenger's side is almost as bad.

My junkyard core support isn't rusty, but for some reason a Florida man cut a small section out of it so now I only have one of the two mounting holes for the fender liner. I'm not sure what the deal is with Florida men and sawzalls. I have a grinder, but nothing possesses me to cut weird things off of my truck.

[Gary Lewis]

It makes no sense to me why people cut things off instead of finding a way around the apparent problem.  

Anyway, I forgot to say that I had Jim, the other elder at church, come over and help me lift the A/C system out.  It was his Holly bush that we pulled out with Big Blue on Monday, so I thought that was appropriate.  And, it took good coordination to get it all out.  It is like dealing with an octopus.

[Steve83]

I managed to remove this, lift it out of a JY truck up on welded rim stands, set it into a wheelbarrow, load it into my Bronco, and unload at home by myself:



But I'm only ~2/3 your age, so still a whippersnapper!

[Gary Lewis]

Wow!  I'm impressed.  Seriously.  

I don't think it was the weight as much as the amount of things to deal with while ensuring I didn't kink one of the tubes.

But I never would have though about doing that had you not mentioned it.  Thanks again.

[Gary Lewis]

I turned a few fasteners today and several parts "fell" off:




Well, to be fair, Florida Man's favorite tool was used in the removal of the exhaust system.  Here's a different look which shows it better.  But, as I was cutting the exhaust one of the welds let loose and a part fell off.  That system has the absolute worst welds I've ever seen.  



And, here's what the engine compartment looks tonight.  The engine is ready to come out when I get the t-case and tranny out.  So tomorrow I hope to get the interior out, which will then allow the shift levers to come out, and then the t-case and tranny.

Speaking of the t-case, I'm talking with the guy that's doing the D60 about having him go through it.  In any event it needs the output flange for the double-cardan driveshaft that I have from when I bought the ZF5, which came out of an F350.  So I'd like him to go through the BW 1345 and make sure it is up to snuff.

[ArdWrknTrk]

1345, 1356 is an $80 kit with a chain.

There's not much to going through one of those.

[Gary Lewis]

I got a bit ..... discouraged today.  I was taking the driveshafts out and the Florida Man had tightened the u-joint restraining straps down so tight I could just barely get them loose with a wrench.  So the first one I pulled off I checked and, sure enough, the joint is bad.

Then I pulled out the double-cardan shaft I have and realized that those joints are bad.  So I watched a youtube on that.  All in all, including the front axle half shafts and the front and rear drive shafts I have something like 8 u-joints to do.

And then there's the engine.  And the EFI.  Plus the fuel system.  Plus....

I say all of that to say that I'm going to have to farm some of this out to speed things up a bit if I want to use the truck next year.  And the t-case is a good place to do that 'cause someone has to source the right output flange and Chris, the guy doing the D60, thinks he can do that.  So if he can also go through the t-case at the same time for a reasonable cost, then I save a lot of time.

[salans7]

I'm only counting seven, unless you're going double cardan on the rear too.

See, it's not as bad as you thought.

[Gary Lewis]

Oh!  I was thinking D44.  Yes, the D60 has 2, the front shaft has 3, and the rear shaft has 2.  Total 7.  You are right.

Less bad.  

[grumpin]

I had a local driveline shop do the double cardan short rear shaft on my Bronco.

$110.00, all painted up pretty and had it done in 4 hours, for a drop in.

I’m not tooled up to do them and I’ve fought many a u joint, so that’s how I’ll do them from now on.