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Re: thomcasey's rescue of #1025 build


pot
It's a twee shaker----choot him choot him
182/1000


Galant VR-4 org Post #: 1197035 posted 12/21/14 01:05 PM     Remind Me!  Send Private Message   Edit Post      
More often then not I usually have to use a torch to loosen the tie rod nut. Its always my driver side for whatever reason. So how is your electrical situation coming along? Were you able to get everything put back together?

Posts: 1386 | From: Fayetteville, NC | Member Since: 10/28/03 | IP: (65.191.158.26) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1197039 posted 12/21/14 03:05 PM     Remind Me!  Send Private Message   Edit Post      
I haven't checked that green/black wire yet. Though I will when ready to finish off the engine harness



Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.165.84.188) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1197469 posted 12/27/14 07:47 PM     Remind Me!  Send Private Message   Edit Post      
Rebuilt the drive-shaft today with new Carrier bearings and all new u-joints.. Looks much nicer and the new carrier bearings will work much better than the cracked and dry originals. Still left the Lobro joint separated since when the shaft is completely assembled, it is too big for the tool room.






Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (2602:30a:c094:91) | Report this post to a Moderator

transparentdsm
I have to say something dumb Member
138/2000


Galant VR-4 org Post #: 1197471 posted 12/27/14 09:12 PM     Remind Me!  Send Private Message   Edit Post      
this was by far the best maintenance i did on my car. i swear it was like night and day and the car handled better and pulled harder. fresh driveshafts are amazing.



138/2000 - BG - Dorothy

Posts: 3375 | From: Klamath Falls, Or | Member Since: 07/27/11 | IP: (24.180.38.35) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1205255 posted 04/01/15 07:49 AM     Remind Me!  Send Private Message   Edit Post      
Been a while since I have posted updates.

Pulled the ABS system and installed a non-ABS setup. Just need to clip all the sensor lines to clean it up at the wheels. The PO or two converted to 5-lug setup using knuckles from a non-ABS DSM, so the ABS system was just adding weight anyway.





Had my youngest helping me remove all the ABS lines, unfortunately he loosened the wrong bolt on the firewall and the AC system slowly evacuated the system overnight, so I just pulled it. I suspect somebody will be interested in the parts.

This is going in today, then it's just the small stuff.


Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (172.9.73.27) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1207431 posted 04/29/15 12:59 PM     Remind Me!  Send Private Message   Edit Post      
Quoting thomcasey:


And this wire. No place for it to go to in the harness:







Went to tracing wires yesterday. Found the Green/black stripe wires are for Sensor grounds, and this wire should run to pin 24 in C-61. There is already a solid green wire there, so it looks like someone already replaced the bad wire, but left the remnants, so that is good news.

I am deep into the RWS delete and have found that removing the rear lines from the front rack itself is much more than I want, so I am fabricating a loop from the flare lines that connect the front rack lines to the lines from the rear. That will do for me until I desire to replace the front rack with a DSM rack.



Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1207710 posted 05/04/15 06:22 AM     Remind Me!  Send Private Message   Edit Post      
Spent some time laying in the driveway yesterday afternoon. I had no helpers for the pull and assembly, but was able to recruit the wife and youngest son (17) to install the new subframe.

Pulled this monstrosity out:


Then installed this 60k mile 4-bolt with poly sway bar bushings and poly camber bushings:



Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1207910 posted 05/07/15 10:12 AM     Remind Me!  Send Private Message   Edit Post      
Did some painting of parts yesterday. I ordered a spray can of Belize green basecoat and a can of gloss clearcoat from AutomotiveTouchup.com for a test. Needless to say from the pics you will see below, the colormatch was awesome. I no longer have a black mirror, a white mirror and a white dogleg. I am very pleased with their product and will continue to use them.

White mirror before ("Gave it a little key" as they say on Wheeler Dealers)


After mirror. two coats of basecoat, three of clear:


Painted white dogleg:


Dogleg mounted:


Should be getting in my new Pressure Plate to flywheel and xfer case mounting bolts in today. Expectation is to get the drivetrain in and done by weekends end. I figure if I am installing a new clutch on a Fidanza flywheel with a new surface that I might as well use new factory bolts. No worries about using 24 yr old bolts here.



Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

iceman69510
Turn Right Racing
855/2000
828/1000


Galant VR-4 org Post #: 1207922 posted 05/07/15 01:31 PM     Remind Me!  Send Private Message   Edit Post      
Good to know. I will be ordering some Belize Green from them this summer.

Ordered some blue for my van, but the color match was not that perfect up close.



91 VR4 855 Nile Black
92 VR4 828 Belize Green-Daily driver status
91 VR4 115 Nile Black -SOLD

Posts: 10402 | From: Michigan | Member Since: 03/05/01 | IP: (205.144.100.200) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1211123 posted 06/29/15 01:16 PM     Remind Me!  Send Private Message   Edit Post      
Finally got around to progressing on this thing. Installed the Oil filter and filled 'er up with some cheap 10w30 dino and spun the oil pump with a drill for about 3 minutes, until all the funky sounds dissipated from the head/lifters and oil flowed freely. Set the timing (No fun cranking that motor around with a standard ratchet and high compression pistons), installed the axles, installed a new yoke on the driveshaft (old one had a slight twist 3/4 way in, so replaced it with a recall fix part) and installed the drive-shaft w/Torque Solutions carrier bearing bushings (a bit of a pain) and xfer case (with new seals). Installed Water Temp, Oil Pressure and Boost gauges in the center console above the radio in the handy-dandy GlowShift 3-gauge din mount plate (still need to connect power, ground and sensor wires.)

Just some final torquing of bolts, hoses, plugs and fluids to install and she will be ready to fire.



Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1212282 posted 07/14/15 01:05 PM     Remind Me!  Send Private Message   Edit Post      
Well, I went to install my twin pot calipers and new rotors and discovered that I did not have both brake line parts from the hard line to the caliper. Also, since the calipers are 2g, I needed the banjo-bolt style. I ordered a Stop-Tech set from amazon for $27 shipped:



I installed them, and when bleeding the fronts, we were not getting fluid to the fronts. Seems my supposedly clean hard brake lines were not that clean, so when bleeding we pushed junk into the stainless lines. After lots of brake clean and several super-stomps, the lines cleared and they were good:




After installing the new clutch master/slave and bleeding the system, I Was verifying the shifter was adjusted correctly and discovered that 5th and Rev were non-existent, even without the cables. Soooo, seems something was broken in it. So, I took my old spare 22-spline 90 tranny to a friends to swap out the output shaft to a 23-spline. Well, it took 45 minutes of prying and hammering to get the axle out that was stuck in it. They used the wrong axle and it wedged the cir-clip in it when it broke off some of the end splines inside the open diff. Well, that compressed the center case a bit, se we decided to replace the center case. Yea, 4 bolts snapped off during dis-assembly. But, once it was opened up, we discovered a couple issues but also some good stuff. BAD: staked nut for 5th gear backed off and was only on with 2 threads, a hole in the top xfer case bolt hole (just under the speedo mount) and a chuck of metal that matched that hole. The GOOD: The gears look fantastic, especially 1 and 2, which are notorious for issues in early 90 trannys, the syncros are a little sticky (maybe oil will help hear once installed and filled) for 3/4, A little more play then we would like in the shift forks but they are still in great condition. We extended the detente springs to get some more snap in there and torqued everything down to spec. FYI, the government changed our pennies. Pre 2000 pennies happily handle 109ft/lbs without running through 5th/rev in pieces, where as 2000 and newer only handle about 70). Tranny is much happier now, and has a 23-spline output-shaft so I can use my fresh xfer case. She just needs some de-greaser and paint to go back in. Thankfully I never filled the tranny with gear oil, so it will be a quick 20 minute swap.

I also got the factory intercooler pipe routing all shored up thanks to JNAVA sending me the GVR4 j-pipe. She is soo close to being finished.

Pre-intercooler piping correction. As you can see, I really needed the stock VR4 j-pipe:


Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1212285 posted 07/14/15 01:15 PM     Remind Me!  Send Private Message   Edit Post      
Forgot some interior pics:





Odometer is for the car the cluster came from, not this one. I doubt the chassis itself has more than a couple thousand more than when 464/2k sold it back in 2009. It was prison raped not too long after and left to live on the streets.



Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

faqinshiet
Member +


Galant VR-4 org Post #: 1212286 posted 07/14/15 01:15 PM     Remind Me!  Send Private Message   Edit Post      
need a stock j pipe? I have one somewhere if I can find it. Just pay shipping usps.



90 GGSX-VR4 clone

Posts: 455 | From: Arlington, Va | Member Since: 12/06/11 | IP: (165.157.121.80) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1212287 posted 07/14/15 01:18 PM     Remind Me!  Send Private Message   Edit Post      
I already got one, thanks. Just haven't got it in there quite yet.



Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1212729 posted 07/18/15 08:13 PM     Remind Me!  Send Private Message   Edit Post      
Had to clean up a replacement transmission. Found the one I installed would not hold in reverse or 5th, something is broken inside. After going through it and cleaning it up she was ready for installation:



Swapped out the transmission and got everything bolted up.. Unfortunately it was 94 degrees and 80% humidity, so the soupy weather sucked the progress out of me in the driveway. Just need to clean up, loom and connect the wiring and juice up everything with fluids.




Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (172.9.73.27) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1213303 posted 07/27/15 06:32 AM     Remind Me!  Send Private Message   Edit Post      
Fired her up on Saturday after replace a bad Wally 255. She started immediately. The wife took the video, so excuse the rotation.

First start-up

I decided after this video to attach the brake booster line, so not the card settles to a 2k idle. Just need to let her run up t temp to bleed the cooling system. Then fill the drivetrain with fluids.



Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1213409 posted 07/28/15 08:58 AM     Remind Me!  Send Private Message   Edit Post      
Got her to idle as she should link

I still need to look into the throttle-body, it is sticky and causing a 1500 idle at times. But, I juiced up the drivetrain and took her for a drive around the block. She is ready for a trip to the Ford stealership where two of my sons work to get her new tires mounted and get her aligned for the shootout. Then install the exhaust and enjoy it!! Here she is parked nose-in in the driveway for the first time, and parked under her own power for the first time since 2010ish.












Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1214347 posted 08/11/15 07:53 AM     Remind Me!  Send Private Message   Edit Post      
Well, Gretchen made it to the Shootout this year!! In less than a year she went from an empty shell full of garbage to a running and driving car. Only had a few hiccups in the 560 mile round trip from Indianapolis:

1. Front left valve stem randomly split when we hit Upper Sandusky, so I installed thae spare and soldiered on.
2. The wheel shop across from the Pizza joint in Wakeman fixed the tire for $12.
3. Rear had a random clicking that I could not identify.
4. The random clicking identified itself on the drive home. Just as we hit Fort Wayne, I lost brakes midway while stopping. Pulled over and found the clicking was the brake line bouncing on the inside of the rim. So, we Vise-Gripped the rubber line shut, zip-tied the vise-grips closed and zip-tied them to the metal brake lines and drove the final 90 miles to home.
5. The alternator was trying to dies the entire trip, but it managed to make it all the way home, even through the torrential downpour we hit around Muncie.

I ordered some new stainless brake lines yesterday, installed the new alternator yesterday and tightened the exhaust to quiet a leak. She will be ready for MOD by the end of the week.






Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

89Mirageman
Senior Member


Galant VR-4 org Post #: 1214353 posted 08/11/15 08:33 AM     Remind Me!  Send Private Message   Edit Post      
And some argue these cars are not dsm's .

All joking aside, glad you were able to limp her home and take care of the problems. So glad you saved this car man, many out there in better shape than yours was when you got it wasting away. It amazes me how far the car has come in such a short time. Great job!



94 Eagle Summit DL coupe
98 Mitsubishi Mirage DE sedan
15 Mitsubishi Mirage ES hatch

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thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1214355 posted 08/11/15 08:52 AM     Remind Me!  Send Private Message   Edit Post      
Thank you. I just could not let it die. Especially since it is Rust Free (ok, except for the surface rust on the rear AGX's, hence the broken bolt and dead brake line) I should have done my due diligence at the SO and pulled the rims to check the rear clicking. I could have saved myself from having to spend $115 for a complete set of stainless lines when I only needed rears. But, that is how I learn.

She will be a derelict for a while. I am not concerned too much with body work yet. It has hail damage on the hood, roof and trunk, plus a few decent dings in the crease areas. I will slowly bring the body back to straight and get her a 10-foot paint job. She will be driven a lot, so she will not be a trophy winner.



Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1223941 posted 02/08/16 06:41 AM     Remind Me!  Send Private Message   Edit Post      
After removing the engine harness, replacing the C-61 connector and replacing the Sensor ground and ECTS wires, she finally fires up right away and settles down to a nice 900/RPM idle I set with link. The new EVO IX wheels roll real nice. Looking forward to buttoning up the little things and installing the AC so the mechanicals can all done before concentrating on paint.






Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)


Edited by thomcasey (02/08/16 10:26 AM)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1225677 posted 03/18/16 09:56 AM     Remind Me!  Send Private Message   Edit Post      
Harness is still flaky. I have removed it twice more and tested all connections. Still causes the MPI relay to flicker over bumps, killing the car and resetting the DSMLink to back to firmware (I need to update the firmware to a better tune than stock). So, bought a new harness off Pot. Hoping for good results.

Also painted the bumper Belize Green using the paint I got from automotivetouchup.com. looks much better.




Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1226076 posted 03/30/16 09:19 AM     Remind Me!  Send Private Message   Edit Post      
Swapped out the current harness for the harness I purchased from Pot. Did it in 45 minutes from start to finish, including the removal/replacement of all panels and glovebox. Impressed myself (although this also indicates I have R/R'd the harness too many times recently to get very efficient at it).

Everything works as it should now (although I get Intermittent TPS errors, I got these before, so I guess the TPS is bad) and I can reliably drive it and give her some WOT tuning now, as she is running stock rich when getting on it. The new harness is unmolested (except for some twisted and taped connections for the O2 sensor wiring that I corrected) so I will take the flaky harness and make it the new/future tucked harness, slowly replacing all the wiring I can with new wiring and shortening everything up to make it nice.



Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (50.58.165.200) | Report this post to a Moderator

thomcasey
I ain't no puny human
1025/2000


Galant VR-4 org Post #: 1227482 posted 05/02/16 05:09 AM     Remind Me!  Send Private Message   Edit Post      
I have had it with what I thought was a stock turbo exhaust (with a 3 " downpipe). Did some measuring and found it was actually a stock NA exhaust. Ordered some 3" pipe, an o2 bung and a v-band set to get my spare Apexi downpipe connected. Time for some welding...









Thom
1991 GVR-4 1025/2000 (PTE 1200's, 16g, DSMLink v3, gm-maf, eagle/ross, .020 over, 272's)

Posts: 647 | From: Indianapolis, IN | Member Since: 09/24/14 | IP: (68.45.230.24) | Report this post to a Moderator

strokin4dr
fighting them with a large needle
1280/2000
1135/2000


Galant VR-4 org Post #: 1227486 posted 05/02/16 10:11 AM     Remind Me!  Send Private Message   Edit Post   
On the dining room table? Damn! haha



Ryan C.
1908- sold and missed.
1280- 2.3, FP 35R, E85, etc.
1135- 100% stock - 88k miles
'93 Mirage hatch- 4g63, AWD, etc (hoarding for build)

Posts: 2666 | From: Savannah, GA | Member Since: 08/30/05 | IP: (161.38.221.114) | Report this post to a Moderator


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