84 Crewcab...AKA..Patches

And it's basically in place now. Just need to fab up the mounts.



The lower mount will use the stock pocket and then run over to the bracket and bushing.



And the upper mount will use the original bushings from the OEM IC.



I will slot the aluminum tag and slip these in like the original ford bushings. Then fab up some brackets to hold it in place.

 
69.5CUDA said:
thats a SILLY tight fit in there...but...im making notes of it all....
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Has to be to clear the grille, with little to no modification. I know the IC is way bigger then I'll probably ever need...but better too much cooling, then not enough.
 
71ChargerRT said:
What Powerstroke is that intercooler from?

Looks great, and I'm also taking notes :2thumbs:
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I believe it's the 99-03 7.3 Powerstroke unit. Has to be the all aluminum one...not the one with the plastic side tanks. If you want one keep your eyes open for a good used one. Yes you can buy new for $400+...but I think I got mine for about $125 shipped!
 
thrashingcows said:
I know the IC is way bigger then I'll probably ever need...but better too much cooling, then not enough.
Click to expand...
There is no such thing as "too much cooling" when it comes to forced induction. Hit that charge-air pipe prior to the intercooler with an infrared thermometer and you'll positively shit a brick at how hot it is. The colder the air, the more power you'll make and the "point of no gain" by further cooling is something you'll never be able to achieve.
 
There's a company already doing essentially that with certain cars: they're modifying the AC system to cool the intercooler. The horsepower gains are enormous-- way more than enough to overcome the parasitic losses from running the compressor.
 
The 5th Gear shift rail came in today...Once again a great piece from Quad4x4!! Got it, and the 5th gear all installed today.



Then it was time to install the 5th gear nut. Here is the order of things that I installed.



-New 5th Gear.
-Then split washer set-up to help hold 5th gear in place should nut back off.
-Concave washer
-New 5th gear nut with brass pins to torque down onto the treads to lock in place.
-Then the splined lock for the 5th gear nut.

With all of this I hope to never have any 5th gear issues...;)
 
So I go ahead and install everything. Here's how the split washer looks when installed.



Used red loc-tite on threads and nut to help hold things in place. I finish torquing everything down...which is a chore if your doing it by yourself on the shop floor, and have no way to secure the tranny....:(



I then realize I may have an issue with the split washer set-up. And the loc-tite had got into the area where the brass pins were to sit and was not allowing them to be torqued down properly. :( So out comes the heat, and I have to pull everything apart again. That red Loc-tite is some evil stuff!!

Finally got it all apart, and cleaned up. That too is a chore. Once clean I did a dry trial run....got everything the way I wanted it and pulled it apart again. This time I had a friend come and help with the nut torque down. A little better...but not much.

During the assembly this time I installed some small pieces of paper towel into the bore for the brass pins. So it would soak up the loc-tite. Then once the nut was torqued down I used my small picks to pull out the paper towel and install the brass crush pins...and torqued them down.

But before you do that you need to line up the nut with the splined nut lock. I had to play with it on the splines until I found a spot where it was just a hair out of alignment. Then I used the 5th gearnut tightening tool, and a rubber mallet, to beat the nut into alignment.

Now it's all done for good!!

 
Then it was time to install the new 4wd tailhousing. I bought a new cast unit...since I couldn't find a new/used aluminum unit. I would recommend you scratch the inside of it if you end up buying one. I used a large screwdriver. I had a lot of small metal debris that was stuck in the paint. It would have eventually worked itself free and could have cause issues internally.

Once cleaned up I realized it did not come with any dowel pins. Good thing I still had the 2wd tailhousing. Few hits with hammer and punch had them out and ready to install in the 4wd housing.



It wash then time to install the top cover, and side PTO plates. Once the top was on I stalled the shifter and ran through the gears. Everything seems to shift fine.

All done.....Finally!!

 
ahh good...personaly ive never liked painting "assembly's" cause i want to be able to see the seal lines and be able to spot leaks at the source instead of wherever the paint allows them out
 
69.5CUDA said:
ahh good...personaly ive never liked painting "assembly's" cause i want to be able to see the seal lines and be able to spot leaks at the source instead of wherever the paint allows them out
Click to expand...

Know what....I never thought of it that way....makes a lot of sense. Oh well too late now...but going forward I might very well do what you suggest. :2thumbs:
 
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