MrFusion

I recently bought a 1992 W250 Club Cab, 4x4, 5spd', CTD truck and am going to start resurrecting it. I figured I would make an on-going thread about my adventures to show you guys what I'm doing and maybe get some advice when needed.
The truck sat for 5 years before I bought it. It has 200k on it and was used to pull a large 5th wheel camper. The biggest problem it has is that it doesn't move in any gear (trans and transfer case). I can shift through all of the gears with the engine running, not touching the clutch, and there is no movement or noise. The brakes held sort of when I rope towed(yeah, yeah, I know) it the mile to my house but need attention. The rockers, driver side rear cab corner mount (?), and driver side floor are rotted. I will probably have to fix cracked cowl corners. The bed is all biffed up near the gate and one of the gate hinges rotted out of the side of the bed. Power steering has no power.

On the plus side: The engine seems to run pretty well. I didn't hear any horrible noises while towing it. It seems to be pretty complete and unmolested. Oh and its a CTD Club Cab!! Not too many of those around here anymore.

Planned repairs and modifications:
The first things to be fixed are the transmission and brakes. After much research I decided that I would rather have an NV4500 than the Getrag. To that end I ordered a NOS NV4500 with updated main shaft and cast iron NP205 adapter, and an advanced adapters conversion kit (bellhousing, etc.) from Midwest Transmission. I also ordered a South Bend 13125-OFEK clutch. They are sitting in the garage awaiting installation.
After more research I decided to convert to Hydroboost brakes. It makes sense to do it now since I'll probably have to R&R the entire brake system. I had a 1995 CTD 2500 a while back and the vacuum brakes on that weren't very good. Parts are in the mail.
I am also looking into adding a power distribution center from another car under the hood. That will give me relays and Maxi fuses. I want the Maxi fuses in order to eliminate the fusible links.
There will be more to come but my fingers are tired and my garage beckons!

mknittle

sounds like a good project.

NJTman

I agree...


and there's not a better place to find out "how" than this crazy people filled joint in space...


If you have the time, patience and determination you can do anything. I sold my previous CTD to a guy in PA who said he was going to "restore it". I laughed thinking "yeah right...."

Boy was I wrong. OMG, It turned out sweet...

Before:



After:

MrFusion

@NJTman-Wow that DID turn out pretty sweet. The rockers in the first pic look worse than mine! That certainly gives me hope. My priorities are: 1. Get it to move on it's own, 2. Get it to stop reliably, 3. Get a sticker on it, 4. Get it to the point where it's trip worthy, 5. Start to play with the performance. My goal is to have it on the road by mid summer. BTW, Does the NJT in your user name stand for New Jersey Transit?

MrFusion

@mknittle- Yeah it should be an adventure. I looked through your build thread a little bit. Looks like quite the project. I'm thinking about converting my '97 XJ Cherokee from RWD to 4x4 at some point. Normally wouldn't consider it in a jeep with a 2.5L but the body is rot free, only minor surface rust in a few spots.

MrFusion

Here's the truck. More pics on the way. I also built the upgraded wiring harness for the headlights but have not installed it yet.

NJTman

Nah,

My 34 year old nickname is " T. " and for the time being, I live in NJ. When I pull my pants off.... ooops, when I look in the box on my wife's dresser, I realize I'm a man...

thrashingcows

Your lack of movement might be because the transfer case is in neutral. If it's not in 2H or 4H then it will not move in any gear.

Sounds,m and looks like it will be a fun project.

mknittle

Could also be a broken rear axle. put the transfer case in 4WD and lock the front hubs in and see what happens.

that is a pretty good looking truck.

user name

That is a good looking truck I'd probably drive it like it is. like others have said it could be something other than the trans. Personally I think dana 70 rear is a weak link though the g360 isn't overly strong.

Looks like a solid project.

MrFusion

I tried all of those things before I bought it (thanks for the ideas though). I thought maybe I'd get lucky and it would be something relatively simple. No dice. I think it's a tranny issue because with the engine running and not depressing the clutch pedal i can shift through all of the gears with very little resistance and no noise. I think if the tranny was intact I would at least hear grinding. Also, the PO mentioned that he lost all but 4th gear at one point while towing his 36' camper (in OD).

MrFusion

Plus I have a brand spankin' new NV4500 sitting in the garage looking for a home. On that note I might have a G360 core up for grabs soon

Jim Lane

Love it, the way she keeps them in a box for you.

If you lived in Ca lifornia you could be CaT man.

Jim

NJTman

Yeah, sad... I know....






Meow !

sooty

ive seen the drive hubs on the clutch discs shear free, are you hearing any spinning gear noise from the trans at all? if its a fourth gear only, 1:1/4th-gear is direct thru mainshaft, pull drain plug, to reveal carnage....