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post #46 of 95 (permalink) Old 11-30-2016, 09:38 PM Thread Starter
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So I dropped a ton of small parts and brackets off to be powder coated; which left me with little to do on the truck, so I decided it was time to start to tackle the rat's nest in the front underhood wiring harness.

This is the main rats nest; about 13 years ago the triangular rubber junction that used to join the main power cable from the battery and all the fusible links together corroded and caught fire; the buss bar and the mess you see here was merely a quick fix to get the truck running again, as it was way up north in the dead of winter when it happened. I remember being in a parking lot of a restaurant and starting up the truck, turned on the headlights/heat and got a big puff of smoke from under the hood---I assume this was a fusible blowing---lost all power, hurried up and opened the hood to find a small fire on the wiring harness. I put it out with snow and we towed the truck back to the farm and rigged it up to run again with this mess; meaning to fix it as soon as the weather got warm....13 years later, still worked; just looks like :butt:. LOL.



Here is the solution; a PNDB module from a late model Freightliner M2 truck. This will eliminate all the fusible links and provide midi fuse protection to the alternator and all of the circuits that used fusible links. This will be much safer and clean things up nicely. I will re-pin new wires in where the chopped ones are now and make a new power harness to the PNDB. It will also feed the glow plug relays on the main supply lug from the battery. I've got the cable ends and connectors/pins for the PNDB ordered up, just need to figure out the pin part numbers in the main cab connector and get a few of those ordered.



I'll be digging thru wiring diagrams here for the next couple hours so I can size the fuses (the ones included with the module are mostly too big) properly and plan out how to make the harness for it. Stay tuned.


1998 Dodge Intrepid
Ram Logistics Director; Danbo Truck & Diesel, Inc.
Chairman; Let Your 2.7 Live Foundation
President, Danbo Drumming Ventures, GmbH;

Last edited by Daytrepper; 04-07-2018 at 09:58 PM.
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post #47 of 95 (permalink) Old 11-30-2016, 09:38 PM Thread Starter
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Picked up my parts from powder coat; CAC pipes, battery tray, and most of the underhood small brackets are buried in that box, lots of assembly work to come this weekend.


Also had the core support done, they were able to match my original paint code almost perfectly.

Last edited by Daytrepper; 04-07-2018 at 09:59 PM.
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post #48 of 95 (permalink) Old 12-03-2016, 01:42 PM
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Looking sweet thDan! Getting stuff powdercoated gets addicting, I see you caught the bug! She's going to look sweet once done, keep up the updates and the good work!
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post #49 of 95 (permalink) Old 12-03-2016, 08:48 PM Thread Starter
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Quote:
Originally Posted by paintballdude05 View Post
Looking sweet thDan! Getting stuff powdercoated gets addicting, I see you caught the bug! She's going to look sweet once done, keep up the updates and the good work!
Thank you Steph! I am considering doing the inner fenders as well. They just about perfectly matched the original paint; and I am still deciding if the match is close enough to do the inner wells. Cant decide if it matches or its noticeable.
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post #50 of 95 (permalink) Old 12-03-2016, 08:48 PM Thread Starter
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Got a bit more done today:

[im




Pretty much down to knocking out that engine harness and PNDB before I can go further. Stay tuned.

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post #51 of 95 (permalink) Old 12-03-2016, 09:12 PM
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Looking sharp - this will be a rebuild for the memory
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post #52 of 95 (permalink) Old 12-04-2016, 10:07 AM
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Quote:
Originally Posted by Daytrepper View Post
Thank you Steph! I am considering doing the inner fenders as well. They just about perfectly matched the original paint; and I am still deciding if the match is close enough to do the inner wells. Cant decide if it matches or its noticeable.
That's a though one. I'd probably air on the side of caution and get them done it a satin/no gloss black to make sure that you wouldn't have the match issues yet you'd have durable inner fenders.

Also, does the truck have AC? I don't see a condenser!? That engine is really shoe horned into that engine compartment, was is there 1/2" of clearance between the valve cover and the firewall?

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post #53 of 95 (permalink) Old 12-04-2016, 12:09 PM Thread Starter
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Quote:
Originally Posted by paintballdude05 View Post

Also, does the truck have AC? I don't see a condenser!? That engine is really shoe horned into that engine compartment, was is there 1/2" of clearance between the valve cover and the firewall?
It does have a/c. Just not installed yet other than the compressor and evaporator. The compressor is going to be replaced its just on there now so the belt can be installed and the engine can be started.

Yep about an inch clearance in the back.
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post #54 of 95 (permalink) Old 12-24-2016, 10:40 PM Thread Starter
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Got a few more things done. Got the engine and front wiring harness refurbished, new PNDB module installed, and all the fusible links gone. Installed new grid heater solenoids. Still waiting on parts for the battery cables, and isolators to mount the PNDB permanently where it sits; hopefully next week sometime they will be here so I can finish putting everything together.



Also, turbo, exhaust manifold, wheel wells, and a ton of other small things went in. Exhaust going on Monday.




Need to find some CAC hoses. Found 2 of mine almost worn completely thru.


1998 Dodge Intrepid
Ram Logistics Director; Danbo Truck & Diesel, Inc.
Chairman; Let Your 2.7 Live Foundation
President, Danbo Drumming Ventures, GmbH;

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post #55 of 95 (permalink) Old 01-28-2017, 08:19 AM
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Looking good Dan, ran across these on C/L

94-01 dodge ram 2500 cummins tow mirrors oem

Don't know if it might be something you could use.
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post #56 of 95 (permalink) Old 02-22-2017, 09:43 PM Thread Starter
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Time for an update.

Got her fired up back on New Years day, she started right up---I was very surprised I didnt have to bleed the fuel system, just filled the filter, and cranked the hand pump a few times. Took a minute for the air to work out, (cant really hear it in the video)....and she runs perfect!
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post #57 of 95 (permalink) Old 02-22-2017, 09:43 PM Thread Starter
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So unfortunately the transmission had to come back out due to an oil leak from the top cover. It has never leaked until now---so after running it and testing everything out, this turned out to be the only leak.

I took it back out and found barely any RTV sealant on anything; other than the PTO covers. I bought a gasket set for it and went thru and replaced all the seals and installed gaskets where there was just RTV (recommended by the service manual, LOL); unfortunately I could not get the yoke nut off--nothing big enough here to break loose 280 ft lbs, so I am going to have to wait to reinstall the trans until I can borrow a 3/4 impact and get the rear cover sealed up. Overall, the transmission looked good inside, no issues to speak of.




While I was contemplating working on the transmission, these showed up:





Decided to upgrade to the 13" clutch and flywheel from South Bend, to handle my future engine mods.

As of now, new clutch/flywheel is installed, along with the bellhousing, if all goes well with the rear yoke nut, trans will be back in next weekend.


1998 Dodge Intrepid
Ram Logistics Director; Danbo Truck & Diesel, Inc.
Chairman; Let Your 2.7 Live Foundation
President, Danbo Drumming Ventures, GmbH;

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post #58 of 95 (permalink) Old 02-22-2017, 09:44 PM Thread Starter
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Latest update; Trans is re-sealed, back in, sent the driveshaft out, had it balanced, replaced all u-joints, center bearing; she's running good. I drove it around the neighborhood last weekend, no hood, fenders, windshield, or doors, she ran great, really liking the feel of the South Bend clutch. Also repaired the ABS with a NOS module, got rid of the lights that have been on on the dash for 10 years. Turns out the HCU went bad back then and blew the integral fuse in the controller.

Next steps are to media blast the fenders, hood, doors, and cowl cover, install the new windshield, and get her ready for the trip to the body shop in May.

Meanwhile, made a few road trips, grabbed some more parts, got it all stashed in the spare bedroom until install;


1998 Dodge Intrepid
Ram Logistics Director; Danbo Truck & Diesel, Inc.
Chairman; Let Your 2.7 Live Foundation
President, Danbo Drumming Ventures, GmbH;

Last edited by Daytrepper; 02-27-2017 at 09:30 PM.
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post #59 of 95 (permalink) Old 02-25-2017, 09:18 AM
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Wow! An amazing restoration! Very, very nice!
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post #60 of 95 (permalink) Old 03-25-2017, 10:35 PM Thread Starter
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Time for an update, the last month or so has been all small stuff, as I'm waiting on the sand blaster to get the hood, fenders, doors, and cowl panel done before bodywork can proceed.

Mostly I've been installing components, cleaning, etc etc.....I've started to restore all the bolts, screws, and nuts for the interior and body; first step, rust removal, then acid dip, then wash, then either black oxide coating, or zinc plating. They are coming out like new; you can see the before on the top, after on the bottom;



Today was the first batch, just have these to do yet;




Also, I tackled the lower shifter boot, which I have been searching for for 2 years, new has been discontinued for 15 years, every used one is torn out just like mine. The first picture is the best used one I could find, still torn. The original was missing nearly the entire center section of the boot. So, searching around, I found a Ford Mustang boot had a very similar design, so I ordered one;

Torn boot;



Old boot cut out of frame:



Mustang boot trimmed up and installed:



It will seal nicely once installed, and the upper shift boot will cover it up.

Other than that, this is about it until the body parts get blasted; hopefully soon.


1998 Dodge Intrepid
Ram Logistics Director; Danbo Truck & Diesel, Inc.
Chairman; Let Your 2.7 Live Foundation
President, Danbo Drumming Ventures, GmbH;

Last edited by Daytrepper; 04-07-2018 at 10:02 PM.
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