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Discussion Starter #161
Part 2








There were a couple of pit stops to let the kits out to wiggle. It was fun to watch them get at it:






Lots of wildlife running around down there:


And bugs! Though at least some of them were pretty:




This is why I think the mercury was a success, we picked up a another kid when the bronco had issues early on. Both boys, and our little girl wound up crashed hard in the back seat with the A/C blasting.


Link to all the photos:
Zenfolio | Sara L. | 3rd ORT 8-12-17 Flat Nasty

Videos from the day:

 

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That's awesome. Although I don't have kids, my drunken friends appreciate the A/C probably just as much as your little ones :)

Glad to see this thing out getting used even with the missfire.
 

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awesome rig, i must have stripped a hundred of these mount/explorers apart when i worked at a slavage yard.
never thought how good of a candidate for a family wheeler they would be.
nice work!
 

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Discussion Starter #166
Sooo... I had some more time to dig into this, and managed to make things much worse. This round...

- Went through more of the harness, didn't find any obvious issues. Every wire that was in the plastic shrouding is like new, the stuff outside of the shrouding (near the connectors) was stiffer, but nowhere near brittle.

- Slapped it all back together, and had a real bad miss, but it wasn't on one cylinder. Backfired through the exhaust frequently and just plain smelled wrong. Really rough idle. I dare say it seemed like it acted like it was out of time?

- Checked the spark, and all was good there (even got hit a few times just to make sure!!!)

- No new codes on the ECU.

So I shut it down and walked away from it for a bit (5-10 minutes) when I came back it'll crank but won't start. Won't try to hit at all, no fuel smell. Check engine light no longer comes on, but the anti theft light comes on like normal. But the biggie is that I can no longer connect to the ECU via the OBDII port. Either my reader just happened to die, or the ECU might have finally died.

Either way, I just walked away from it very frustrated again tonight. I would think that if the ECU was dead, it wouldn't let me crank it, but maybe that isn't the case? Not really sure where to go from here, and I'm quickly getting tipped towards the scales of just parting the damn thing out since I'm getting tired of spending more time in the garage with it rather than wheeling.

Thoughts?
 

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Electrical problems are the worst. But don't let what is most likely a dumb solution you haven't found yet make you throw in the towel.

If you haven't already, a message to EFI Guy over on classicbroncos.com may be worth it. he has these OBDII small blocks down pat. He has helped me out more than once.

His profile LINK
 

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Discussion Starter #168
Electrical problems are the worst. But don't let what is most likely a dumb solution you haven't found yet make you throw in the towel.

If you haven't already, a message to EFI Guy over on classicbroncos.com may be worth it. he has these OBDII small blocks down pat. He has helped me out more than once.

His profile LINK
The towel is in hand at this point, but that's mostly me just :crybaby:

Thanks for the lead, I sent him a message this morning. Fingers crossed that he has something for me.
 

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Discussion Starter #169
So it’s back alive again. I’m my own worst enemy at times…

Turns out I popped fuse 19 (Power to the PCM). My best guess is that it happened while I was dicking around with the Ignition interference Capacitor circuit as I was working on cleaning that connection up, so it is entirely likely that I grounded that out while playing with motor running swapping plug wires around. That’s my best guess anyway.

I also had # 1 and # 3 wires swapped, once I had that fixed, it started running much better :homer:

So now I’m back to square one again that it still runs fine, except for the intermitting misfires that I’m dealing with, which is better than being dead in the garage.

I’m playing phone tag with the EFI guy to see if he can help it out. Maybe the damn thing just needs a tune after all....
 

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LOL, nice build thread, btw. I own a 2000 Merc and use it as a daily and family adventure vehicle, while I have a heavily modified '79 Bronco for more dedicated offroad tasks. I do love the Merc however and have done a few minor mods to it.

My '79 is injected and uses EDIS coil packs like the Merc, I had a very strange and irritating misfire for a while as well and it ended up being the filter caps on the ignition as well. I created dedicated ground straps from one bolt mounting a coil pack to a good ground, problem solved. The packs rely on their ground through the mounting bracket. Another situation I had a friend needing work install a 1" phenolic intake spacer on the Merc and a similar misfiring issue presented itself again. This time, he had simply forgotten to reattach the filter cap connector altogether!

Not sure what real options you have for tuning the EEC-V, as it's likely a REAC3 or REAC4 strategy computer. I believe that Pops Racing will see you a strategy for around $200, but I've not seen one yet so I can't attest to the quality of the work there. SailorBob's strategies are some of the best I've seen and it would be hard to top that work. Do let us know how the tuning aspect of it works out, however... and if you need help with that, as I've tuned just about everything including aircraft engines.
 

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Discussion Starter #172
So are those stock waggy front leafs you used?
Yes. Stock height replacement pack from Crown Automotive. They have a slight arch to them still while weighted down.

If you haven't already, a message to EFI Guy over on classicbroncos.com may be worth it. he has these OBDII small blocks down pat. He has helped me out more than once.

His profile LINK
Big thanks again for this lead!

I called him up and picked his brain for an hour or so. In the end I wound up shipping out the PCM to have it reflashed by Gary. He got it turned around very quickly to me so that I could get a few miles on it before heading west. After 120 miles, I can safely say the thing hasn’t missed a bit, and the drivability has improved greatly (not that it was that bad before).

So even though everywhere I read said you don’t “need” a tune when swapping in a manual (With the '99-'01). It turns out that you do. Lesson learned.

I'm happy enough with the thing now that I actually washed and waxed it before running it across the scale:


5,750 lbs without passengers, 8 (ish) gallons of fuel, no tools, and a spare in the back. I'm going to try to run it across the scale again "Vacation Ready" to see how porky it gets. My guess is 6,500 lbs loaded for bear.

Thanks again everyone for working this through with me :)
 

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Wow, that's a good 1200 lbs heavier than the stock vehicle!
 

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Glad to hear Gary could help you out! he makes it sound so damn simple and he alone is probably the single reason v8 explorers are becoming an endangered species. Everyone is ripping the drivetrains out to swap them.
 

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Discussion Starter #175
Wow, that's a good 1200 lbs heavier than the stock vehicle!
Which isn't too bad when you think about it. The 37's/D60/14 Bolt weigh that much just by themselves. Then add in the weight from the doubler, and some armor.

Glad to hear Gary could help you out! he makes it sound so damn simple and he alone is probably the single reason v8 explorers are becoming an endangered species. Everyone is ripping the drivetrains out to swap them.
It wouldn't surprise me, and it is funny you mention that. You don't see as many of them on the road as you used to.. But then again, the newest one of this generation is 16 years old now.
 

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either of you got Gary's email? I think shipping my ranger's PCM to him would be a huge help
[email protected]

Talked to him the other week myself about flashing my computer since I removed so much stuff from my harness. He's a good dude, told me to call him directly to go over what I wanted.
 

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Excellent news regarding the PCM flash. That may be my issue as well, however I'm pretty sure I swapped PCM's (to one with a manual trans) when I did my engine swap. May be worth a call once I get the rest of my stuff straightened out.
 

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Discussion Starter #180


Well we made it there and back without any real issues. I'll post a trip report sometime next week if I can get unburied from work for a bit.

Overall the truck did well, and the kids handled the trip out there an back much better than expected :) I've got a couple of issues to hammer out before the next off road trip in October, but nothing too serious.
 
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