What did you do to your truck today??

[special-K]

I never had any problems out of my '92 dash. Never any cracks or need to repair anything. What I didn't like about the headlight/parking light switch was they weren't considering flashing semis when they are clear with that design, which I always do. You have to shut all the lights down to flash the headlights off and on. With a post type switch or a dial you can just go from headlamp to parking lamp and back

[Just call me Sean]

You have to push/pull the left side of the headlight portion of the switch to flash them. I only flash them for speed traps.

[special-K]

I've always driven with the semis in mind and help them any way I can. Hitting the left side shuts all lights down, tail lights and all. There is no way to only turn the headlights off and on while leaving the running lights on.

[Just call me Sean]

I do it all the time. Pushing the right side shuts all lights off. Pulling the lower left shuts off just the headlights, pulling the upper left shuts all lights off. Pushing the upper left turns on only the parking lights, pushing the lower left turns on all lights. It's a funny switch but it does operate to motor vehicle standards.

[Just call me Sean]

On my way to work my ICM malfunctioned which caused horrible misfiring which caused my muffler to explode... again. I limped a short distance to AutoZone and exchanged the ICM. Now my truck is loud.

[pjmoreland]

The steering on my truck has been binding slightly occasionally. It sounded and felt like it was coming from the column. I bought a replacement column from a low-mileage truck at a local wrecking yard. I had to disassemble both my original column and the new column because the shroud that the gear shift indicator cable clips to was broken on the new column. While disassembling the columns, I discovered that one of the bearing retainer cages was installed backwards in my old column. It was also broken, and there were loose chunks of plastic in there. The bearing cages have a flange on them that is supposed to be inserted inward. The flange pops into a groove that is just past the bearing race. This retains the bearing cage and keeps the bearings from falling out while assembling the column.

I now realize that my old column was quite worn out. The shifter and ignition switch mechanisms are much tighter in the replacement unit.

Oh, and I just noticed the zip ties on my brake pedal, so I've got a new pad on order at the local Chevy dealership for $3.

[Boog]

When putting the column back together use a bit of lock tight on those 4 countersunk screws down in the knuckle area to keep it from working loose too.

[pjmoreland]

Originally Posted by Boog

When putting the column back together use a bit of lock tight on those 4 countersunk screws down in the knuckle area to keep it from working loose too.

Good call. I put blue loctite on them. I really don't want to take that column apart ever again!

[Just call me Sean]

I thought my starter was bad and it probably was since sometimes it only clicks, so I changed it and after a lot of grief today I discovered one cylinder is filling up with water. So I have a blown head gasket and/or a cracked head.

[pjmoreland]

Originally Posted by Just call me Sean

I thought my starter was bad and it probably was since sometimes it only clicks, so I changed it and after a lot of grief today I discovered one cylinder is filling up with water. So I have a blown head gasket and/or a cracked head.

No!!!! I'm sorry to hear that!

[Just call me Sean]

Thanks. I got a picture of the mess all over the nose. I'll start taking it apart in the morning.

[Just call me Sean]

I've got it apart. Water was getting in at least cylinders # 1, 4, 6, and 7. Drivers side head has an obvious crack. I need to inspect the passenger head and block better.

[Just call me Sean]

So... I'm at the point where I'm going to park it and use the 99 for work temporarily. I worked on it all weekend up to 4 AM Monday morning. Initial test drive wasn't great. The head I used was a bit crusty from sitting, I cleaned it up and sprayed it down with WD40 before I installed it. At 4 AM with no muffler I didn't drive it much especially with the way it was running, pretty sure the valves were sticking and it took quite a bit of cranking to get it to start the first time. I got a couple hours of sleep and figured I would see how it does when I went to the gas station in the morning. It was better, I figured it needed to work through so I took it to work. The further I went the better it got, the temperature was good. Then today, it was still running pretty good but when I got to the gas station it was leaking water. It looked like the heater hose so I figured it tore when I removed it so I cut off the end, put it back on and went to work. At work, I see it's still leaking. I only noticed the leak in the first place because I've been checking the flywheel teeth for damage every time I stop so I wouldn't have to turn the engine by hand. The flywheel is damaged, it's missing at least one tooth from me cranking it with the cylinders full of water. I'm hoping the leak is just the fitting which I've changed before. Then I get home, I've been smelling gas and when I got out to open my gate I hear the gas cap hissing. I take it off and it lets out lots of fumes and if I put the cap back on the fumes immediately build up enough pressure to make the cap hiss again. The exploded part of the muffler is facing the gas tank. The heat from it has melted a part of the plastic skid plate and is heating up the fuel in the gas tank to where it pressurizes the tank.

So in short, I need to change the flywheel, change the muffler, and fix the water leak before I can start using it again.

[DeadheadNM]

Man that’s a bummer. Hope that’s back on the road before too long.

I didn’t do anything today but did get some fresh GM door handles in. Dates are 2020 and 2021 assembled in Canada.

[Just call me Sean]

Thanks. The flywheel will be the fun part. I'll do that this weekend if I don't get to it sooner.

The water leak seems to be fixed. I removed the fitting and it looked fine other than the tip was crusty so I cleaned it up, put new Teflon tape on it and put it back in. I think I didn't have the hose clamp low enough so it wouldn't seal on the crusty tip. I also cut off the muffler, I'll order the new one tomorrow.

[special-K]

I'm surprised my muffler hasn't exploded yet. Probably because it's a Flowmaster. couple years ago a donut gasket started leaking and it give a big backfire if I wasn't careful letting off at speed. It started leaking again a couple months ago and the big BANG came back. Fixed it again, no big BANG. A new system is on the list. No tailpipes, straight off the muffler now.

[Just call me Sean]

Flywheel is out. Here's a picture of the worst section.

[Just call me Sean]

Flywheel is installed, everything is together. Now to work on the muffler.

[Just call me Sean]

Muffler is on, oil is changed, everything is together. Haven't ran it yet. I was going to mess with the starter but while I was cleaning up the garden hose burst and got everything under the truck wet. It's too cold to be laying in water. I've had issues with the starter for a long time, reading the installation instructions mentions a 1/8 inch gap and mine has over 1/4. So I check my van and it has 1/8. I'll see if I can shim it closer tomorrow, otherwise the other solution I've found was to grind the mounting surface of the starter.

[Just call me Sean]

So I pulled out of my gate to go exchange the starter and my van caught fire. I'm not sure why, but I did get it extinguished fairly quick. Damage looks minimal. Wires don't look like they shorted out, just melted from the fire.

[hatzie]

That AC box might be miserable to find a replacement for.

[Just call me Sean]

Originally Posted by hatzie

That AC box might be miserable to find a replacement for.

I have a cracked one on my parts van if I can't find a better one. The coolant reservoir also burned up and I'm not sure where the parts van one is. It doesn't seem to be available new.

[special-K]

Bad luck! I guess that fire started up pretty quick if you were just pulling out of your driveway.

[hatzie]

The 93 & prior surge tank isn't pressurized. If you can't find the 15588837 in used or new condition you can probably source something similar and fab some brackets.

I'd go on an expedition in the pick and pull. There are a bunch of overflow bottles on Japanese & US SUV, Truck & Van chassis that might fit the bill.

This little beast used on the Honda CRV might be a possibility.
https://www.amazon.com/Overflow-Expa..._df_B07DNJG1TY

[Just call me Sean]

Up to 91 is available, mine's a 92. I'm not sure what else would be needed besides the bottle to make it work. Mine has a special bracket.

I think I know what happened, according to online research. My blower didn't work well, and the evaporator case was filled with leaves. I mean full. I pulled out a bunch and I'm sure a bunch burned up in the fire. When the blower doesn't work well the resistors get hot and when they are surrounded by leaves they ignite them.