12v Excursion Redo

[DVolk]

How do they work out with a manual transmission ? will the stock guages work and what not ? , i cant afford to drive the V10 other than the t case i id have the parts for the other direction need somp pics of a 5 spd in a excursion

 

[therabbittree]

Dvolk, Excursions work nice with manual trans. There are a few thread out there with converted excursions. some of the wiring is different from a truck so when you do a full a swap and want it perfect you need to do some cutting and rewiring. I don't know exactly how / what the previous owner did to it , and I don't think it was done perfect. I had to redo alot of it and still have some issues. This truck was converted before I had bought it. It had NV4500 and dual disk pulling clutch. The Previous owner did not get the speedo to work. I thought it was bad diff sensor, swapped that and haven't had a chance to try it yet lol as its been sitting since 2009.

As I mentioned I am truing to get the truck on the Road ASAP to use it as a family vehicle and my new Plow Vehicle. We are trying to close on a house and it has 1100 foot up hill gravel driveway etc so a dependable plow vehicle and v plow will help ALOT. Its already dropped into the 20's a few evening and I hope to get the gold excursion on rd before snow flies. Our Other Excursion is still in body shop...... Friend helping a friend repaint turned into months in shop. Truck has been in since Feb...... Friend says he hopes to have it done by Halloween. I take that to mean Thanskgiving the way things have been going. So with 4 kids fitting in my dad's 2002 2500 Dodge Excab its tight fit for 6 people!!!!! The Other Excursion is a '05 Eddie Bauer. I rebuild the engine last year $14 k later all bullet proofed, full engine rebuild, regulated return, remote fuel and oil filters. A1000, welded deleted intake, BPD remote oil cooler etc etc. I have along build thread over at Powerstroke .org. Here's the link if your interested.
http://www.powerstroke.org/forum/6-...n/403050-05-excursion-cab-driveway-build.html



Photo Bucket is sooo slow!, that stated I have been working on it. 4 hrs to upload 20 pictures???
- Wife with our youngest - inspecting the progress
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- The old twin turbo project is way to much of a pain to finish now. So Removed it. I cleaned up a old ford F800 rear drop manifold I have, and the turbo from my first gen plow truck. H1C with map width groove, and 12cm wastegated housing. Have to fab the oil drain. and drill tap for pyro etc. Cleans up the engine compartment.
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- The truck had a school bus center fan pulley and would not fit a regular fan.I removed the dual electric fans, and swapped in a dodge fan pulley and a 1st gen clutch fan . like that better as less stuff to screw up. Just need to get a fan shroud to fit...
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- I cleaned out the interior as it was a storage shed for the last several years argh. I had ordered a ACC ( Auto Custom Carpet) Black vinyl floor years ago. I ordered 2 yards more of the same material so I could make a removable floor section around my fabbed transmission hump. lol. The transmission hump seems to fit well when I built it a few years ago. but now I can't seem to get 3 holes to line up perfect.
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- I am not going to redo it again as I'm very short on time. So I bolted it down, and sealed it up . I was going to buy a boat load of dynamat type sound insulation to and do the whole interior. But again lack of funds and need for vehicle on the road ASAP curtailed that idea. The ACC kit comes with the Jute floor insulation but not much. No Instructions and the vinyl is not molded or cut . So its all guess work and hand cutting. Laying it in the sun helps but when its chilly in the fall the vinyl is stiff. The Shifter boot I think is from a Dodge? I have two styles here a rounded square and a square style.. I mounted it up and used a Gripper Shifter I bought used. The Knob will be a push button style to activate the 4" remote pacbrake. I don't like the feel of the knob so far and may just make it a nice Cummins ball shifter from Genos, with a push pull switch mounted on shifter.
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- I want a 60/40 folding center console front bench seat. Found a nice leather heated power one but its $700 .. so found a clean cloth non power one in the junk yard. debating swapping it in whole and putting seat covers on it, or just swapping in the center seat / console in with the leather buckets i have now. You can remove the inner armrests on the buckets to make it work but its not pretty but works.. an it fits my limited budget.

- The 10.5 Sterling rear in the truck had a leaking rear cover . I pulled it and found the ring gear was chipped. Its 4.10 ration. has 135k on it. Found a 77k 4.10 rear from a 2000 F250 gasser. It was REALLY Rusty but clean inside. Took a day and beat / burnt the rust off. Primed and painted it. The Gasser diff and some early diesel diffs had a regular yoke instead of a drive flange. Researched and found I can either unbolt and pull the yoke , then re set the pinion with new crush sleeve and set it up again or take the drive flange off my rear drive shaft and just put the u joint in the rears regular yoke. That is much easier!, supposedly it only makes the rear drive shaft compress 1/4 " the slip yoke should take that no problem. When I get $ I will get the Dana 60 SD front and this rear regeared . with lockers and either 3.31 or 3.55's. any thoughts?
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- Have to swap in the rear and do the rear brakes. debating pulling the brakes from the truck off and saving $ or buying new .. new is easier but it needs full re brake, dorman backing plates, calipers, rotors, lines and hoses etc... have to see...

- Ordered '05 and up harley style head lights. I need to cut the header panel to fit them and updating the wiring pig tails etc...

Thanks,
Deo

 

[therabbittree]

- Had to cut down and lengthen the driveshafts - repainted them and look nice.
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- Started to make a rear bumper for our 2005 and stopped. decided to use it for the 2000. It need to be modified, I built it off the truck and it has to be adjusted and filled in a few places. I plan on installing rear back up lights in the bumper some where too. Maybe a rear spare tire gate??
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- Cleaned up , and painted the NV271, have to swap it with teh electric shift NV273 and source the linkage etc.
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Thanks,
Deo

 

[DVolk]

Mine has the centercouncil init so i want to know if the shifter would interfear with that as i dont want to buter up the interior if thats the case ill just use the slush box and fork out the cash for the adpter plate programer and engine mounts

 

[therabbittree]

Donovan, The Center Console fit with te nv4500 and cleared the shifter fine. I had a lot of pictures but my computer crashed years ago and i lost a lot of them. The Shifter may have been heated and adjusted. I just took out the console to do the new floor. I like the bench with the center fold down jump seat console so i could fit 8 people , 3 3 2 .

- I Pulled the rear and swapped in the other rear tonight. I have to do brakes. the old rotors are really rusty and the pads delaminated from rust. Nervous about the calipers.The calipers look ok, but never know. Gonna do new backing plates, e brake cables, e brake and e brake hardware.

- Dropped my snow tires off to swap them onto some 8x170mm sd wheels. Picking them up tomorrow.

- My '05 Harley headlights came in today. I'll have to cut the header panel. I ordered a harness with relays and plug adapters to adapt the 2000 plugs to the 2005 lights.

- I have to pull front wheels and check the front brakes, get the track bar to bolt up - its almost there just needs a little give. Do the Ball joints.

- Have to measure for shocks and get a set from Cary T, at ct performance.
Thanks,
Deo

 

[DVolk]

If you have a enterior pic you can take id like to see it , what mounts for the engine ? are used and intercooler , that fan looks real close what year of fan hub is that ?

 

[therabbittree]

Like I said in the other post , my computer crashed and I don't have a interior picture from before the removal of the NV4500. If your looking for a standard trans interior picture look up a truck with center console and manual trans the excursion and pickups are the same drive train wise.
- The mounts were home made using 2nd gen dodge engine mounts.
- Ford 7.3 Super duty intercooler.
- The Fan hub is from a 92 dodge.
Thanks,
Deo

 

[DVolk]

Did you have to change the exhaust manifold , what did you do to the 2nd gen mounts , i have a set of those already

 

[therabbittree]

Donovan,
The Original builder of the truck mounted a 12v ATS exhaust manifold flipped and had a hx50 with 6cm turbine housing on it. Here are afew pictures of how he had it.
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I have shows several different pictures in this thread regarding my turbo setup. I originally was going to do a twin turbo with hx50 and 9cm turbine and a ht3b 27 turbine. Currently the idea is to use the rear drop mount from a f800 ford similar to a 3rd / 4th gen. and a h1c 12cm turbo. Trying to keep it simple and quick to build.

Regarding the engine mounts here are some pictures. Again the previous owner built them. 2nd gen doge engine side and steel plate fro crossmember side. Used the engine from a '96 school bus and a nv4500.
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Hope this helps you.
Thanks,
Deo

 

[therabbittree]

Friday I removed the rear axle with the chipped ring gear. I installed the other 77k mile rear end. I order new brake parts as the rotors , backing plates , and e brake parts were toast.
I Went to the Junk yard Saterday and was hoping to pull the nice bench seat with the folding jump seat center console setup. Well they crushed the truck.. ..so I am using the front captains I already had, but without the center console. So it will be like a van lol.. I hope to find a nice folding jump seat setup sometime in future, but for now the two Capts. will work for now. I reinstalled them and found out my batteries are really dead, and I can't move the drivers power seat backward lol.. My small trickle charger died, along with my large roll around charger.. more $ to spend.
I was able to source a nice ford plastic fan shroud from a 7.3 power stroke sd truck. The Shroud won't fit with radiator installed. It slides in with rad removed, but it got stuck trying to remove it. I modified it with a grinder on the bottom to gain more clearance and measured 8" down from the top on either side and cut it in half. I made up some aluminum flat stock, riveted the stock to the lower part of the shroud, and drilled and used 8mm self tapping screw on the top part so it can remove the shroud easily in the truck with radiator installed. It got dark so I'll take some photos and test it out tomorrow.
Thanks,
Deo

 

[DVolk]

I wish i had the jigs to weld up a set of those mounts that save a huge hassel although the wife says she wants to stick with the auto , so oh well i guess thats what we do

 

[therabbittree]

DVolk - You can buy different mounts from several vendors. I like the mounts that use dodge style engine mounts. If you can use a leveling bar on a engine hoist you could set up your own mounts. Basically how this guy did it. Cut some cardboard and test fit and then transfer to steel. If your gonna do a auto I'd recommend having the trans rebuild with upgraded shafts and tighter convertor etc. I'd go with a dodge trans and you would save yourself adapter headaches etc etc. A Built Trans is a about $5 or more.

- Worked on the truck and discovered the fan shroud I was playing with won't work as the fan blades will hit it at the top. Frustrating to mess with and waste lots of time and effort on it.
- picked up alot of parts and was shocked and semi ****** on the price of some of the parts / seals on these trucks.. the front axle seals are like $50 a piece!, bought batteries and the price has gone up last few years.. $150 each. Ouch bank account $1300 lighter.....I am hoping the front wheel bearings are good and same with teh calipers argh... lol

Thanks,
Deo

 

[DVolk]

Ive thought about a engine leveler for some time just got to find one that is strong enough . Ive also thought about the hood lift for a cherry picker , Im not shure how to get the dodge transmission to talk to the ford gauges ?

 

[therabbittree]

I've Been working on it, Loading Pictures Sucks. Seems like Photo Bucket is like purgatory lol. So no pictures yet. I took a bunch, so I will post them later.
Got the Rear end swapped in, and the brake brakes done. I was struggling with the drives side e brake setup , and couldn't get the drum setup to work. Then it dawned on me the cast iron top fulcrum had rusted the inside ears off. The Drum pads wouldn't stay put because of it. Lol I had to rob the other rear end for the axle mount, clean it and paint etc. got them in.
Mounted the modified trac bars. The original ones hung way down and were double bars. Cut them down to one bar. The kinda suck with ag ends that are frozen etc. but they worked and it was "free" so I'll rock them till I can do another set.
Put the 4" exhaust back under the truck. I have to add the 4" in line muffler, and the 4" remote exhaust brake too. Gonna have to ad some extra hangers. The exhaust is home made 4" steel no muffler. I would like a stainless Magnaflow 4" system like my '05 excursion, but that's $ and I am on a budget.
Swapped the 271 in . Now I have to Fab up a Transfer Case Shifter mount to the G56.
Put the new Deka Group 49 batteries in. These batteries had a wider top then the old 49's it had. I had to cut and grind the Drivers fender, hood corner to get them to sit down in the mount I built.
Gonna tackle the front brakes, Ball Joints, and u joints today. I hope the wheel unit bearings are good. Debating on putting new ones in for piece of mind? but that's $600. Gonna look up the greasable unit bearing mod now..
Off to work on it now.
Thanks,
Deo

 

[therabbittree]

- I finished up the ball joint and brake job up front. Used some warns i got from the junk yard. I plugged the vacuum lines to the hubs.
- I mounted the h1c 12cm wastegated turbo on to of the the flipped 12v ATS manifold. I had to heat up the ATS and separate the ends again.. That really really sucks. They have to get almost cherry hot and using a blow torch tip doesn't heat as evenly ...beating on it o broke a ear off and had to heat it and reweld it. No fun. the Turbo is really tight to th ea/c box. Its the wastegate linkage. I'll see if it hits.
- I had to make a oil drain, I had to get it to clear the compressor housing and the turbine mounting ears. I Extended it down to only use a short piece of oil rated rubber hose.
- I made a new cold side to intercooler pipe.
- I had to clean up the old intercooler to intake pipe it was pretty rough.
- I ordered 6 Bilstein shocks from Cary T 2 each side up front and 2 for the rear. Ordered an adjustable Trackbar from him too.
- Received my Transfer case shifter boot from White Bear Ford. I was happy to see the $35 boot included the inner boot / seal, and the plastic lower mount, and the 4 phillips head screws!!! Those screws are what normally suck. You can't ever get them loose at a junk yard.
- Test fit my Redone drive shafts and found the rear is totally compressed and unable to fit at regular ride height. I rechecked my measurements and i was off by 1 inch. 1 inch shouldn't have made that big of a problem as the slip should have some decent travel. I had the truck up on jack stand during test. I have dropped it down and plan to re test fit today. I think the rear has to be shortened again. Argh.
- My Fittings for fuel system should arrive by friday. I hope to get it done asap.
- I changed the oil and filter running the kendall 15-40 synthetic blend.
- Installed new upper dodge 12v rad hose. Did the lower hose using 12v first gen lower hose jointed with a 2000 Ford SD 7.3 lower hose, Had to trim them up a bit and use small steel exhaust pipe adapter in between them. Worked great. Much better then the contraption that was on the truck.
- Started to put the fender liners back in. I have to sort some of the wiring - rewrap the ac compressor and pressure switch harness, do the grid heater wiring, reroute the gauge wiring. I have to mount the vacuum pump an go throw the hoses. I have heard I can ditch the vacuum tank.
- I run to the fastener supply store and by some bolts. Need the tow hook bolts, the clutch slave is missing a mounting bolt. The G56 had reverse torx mounting bolts fro the PTO covers. I would like to swap to regular head etc.

Pictures and more updates soon.
Thanks,
Deo

 

[therabbittree]

More Progress, lots of Rain and now freezing cold lol....

- Got a Eaton gear lube filter on the passenger side. I had tried to fit it with a Fast Cooler on the passenger side , but it wouldn't allow 4" exhaust to fit by. I moved fast Cooler to the Drivers side of trans and used one of Ahale's old Plexiglass pto covers. Swapped all the inverse torx bolts to regular heads. Bought 5 gals of 50wt syn gear lube. no more ATF. I had to pull the exhaust heat shield off too.

- Found out the drive shafts aren't right. The Front is ok, but the rear one is too long and is compressed before it can even be bolted in. no good. Dropped it off for the shop to redo. I got a tap to chase the yoke threads front and back and new bolts / straps.

- Got my Shocks from Cary T. The Bilsteins are nice. kept the dual BDS front shock mount from the old 8" lift. So I've got 2 per corner in the front. The Icon front Tracbar set up is Super Beefy! Bolted that in. Need bump stops front and back . thinking of Timbrens, especially with the 9'2" V Plow. Timbrens or air bags in the rear?.. I'd like a rear sway bar too. This excursion didn't have one.

- Redid the front intercooler piping and painted it.

Whats left to do :
- Have to bolt in the intercooler piping.
- Fill engine with coolant.
- Fill trans, and transfercase
- Bleed brakes.
- Mount clutch slave and bleed
- Bolt in down pipe.
- Mount Remote 4" Exhaust Brake, and make some new exhaust hangers.
- Fab up a transfer case lever mount on the trans,
- Bolt in Driveshafts.
- Plumb the dual feed p pump fuel lines.
- Straighten out wiring and reinstall drivers side fender liner.
- Cut the header panel for '05 -07 headlight conversion. Install the '05 harley lights and wiring relays.
- I have to pull the front lower crash bar under the front bumper to mount plow mount.

Hope to get it going before Thanksgiving!?? , We are finally Scheduled to Close on our new house on Friday afternoon so I have some work there too.
Thanks, and Happy Thanksgiving!
Deo

 

[therabbittree]

Fired truck today :ft:

I Still need to finish a bunch of things, but it was nice to hear it start.
Hoping the clutch slave will work, the fluid may have drained as the reservoir was empty. I'm hoping the line was full.
I have to rig up the grid heaters, make a transfer case shift lever mount that goes on the side of the g56, re try mounting the drive shafts, finish little wiring jobs etc.
Hope to get the plow assembled and mount attached this week. I took the week off to try and get it done.
Updates soon Son.
Deo

 

[DonFitzwater]

Cool. Keep at it!

 

[therabbittree]

I Finally uploaded some pictures. I hate Photo bucket. What other photo hosting do you guys use? PB is so slow its horrible took all night to upload 60 pictures. and even crashed the browser.

Last I had posted I was doing the Axle swap to fix the chipped ring gear.
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Swapped a 10.5 from a 77k mile plow truck in yard. only issue is it had the regular rear yoke instead of flange yoke so i had to remove the flange on driveshaft.
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Redid the rear brakes. all new dust shields , rotors, drum ebrake etc
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[therabbittree]

Added new shocks front and back used Cart T's special valved bilsteins. CT perfomance. I don't have shot of the rear. the double front shock mount is from the old BDS lift kit it had. looks like they press out the single bolt and use a longer one pretty simple to mod a stock mount to be double.
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Made new Radiator hoses up and got rid of the silly hose it had for the lower.
The upper hose is a 2nd gen 12v hose.
The bottom is a mixture of a 7.3 lower hose and a 1st gen dodge lower hose you just cut some hose off of each and join them with a exhaust pipe adapter.
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Worked on the fuel lines. Using the synflex air line hose from tank and to filters then to the lift pump. 1/2" feed, and 3/8" return. Made the rest in teflon lined hose with reuseable fittings. the feeds at Dash 8 / 1/2 jic and return is dash 6 / 3/8 jic. Made a dual feed set up. the t i drilled and tapped and added a pressure gauge. on the return side used dash 6 banjo and made up a transfer block from a steel log fitting npt on exit and 3/8 jic on entrance. tapped it to fit the return banjo bolt fitting. its 8x1.25 I believe ( i posted it in the fuel fitting thread in dodge competion over on Competition Diesels web site) . Welded a bracket to bolt it onto intake plate and it works great. I cover my stainless hose in clear vinyl to prevent chafing and it looks clean too.
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Thanks,
Deo