Another Bittersweet Day

I've been doing little things here and there to the truck. Each one seemed to help. I put on a new distributor cap and rotor, replaced the vacuum advance hose, and sealed the distributor cap with dielectric grease. I wanted to try to recreate the stalling issue so I could troubleshoot the issue. I started out driving around the the block for a while. No problems.

I decided to run by the store to see if they had the coil pickup in stock. They didn't and the truck didn't want to start when I came out. This situation didn't really fit the issue I was trying to recreate, but I decided to start running through my checklist. The accelerator pump was squirting gas into the carb; however, the fuel filter was almost empty. Is it possible for the accelerator pump to be working, but the carb not to be getting gas? I was cranking it over, trying to test the ignition, and suddenly the fuel filter filled up and the engine started.

The fact that the situation was not really the same and that this appeared to be related to a fuel issue makes me think that this may have been a different issue altogether. It has always been a little hard to start when hot. I wonder if the fuel is boiling in the line when it passes near the exhaust manifold.

During this whole process, my frustration with the starter reached the breaking point. I was tired of thinking about the stalling issue and I was tired of the started not catching, so I decided to pull the starter. Turns out that problem may be an easy fix. I was worried that the ring gear was missing teeth or worn, but the gear on the starter is obviously the problem:

One great thing about replacing parts like this is getting the lifetime warranty. This is the last time I'll buy a starter for the truck.

So I'm not any closer to solving the stalling issue, but my starter issue is going to be easier than I thought.

Headliner Project Phase 1

As I mentioned, I got a headliner with trim and hardware off a donor truck.  The headliner tore during removal, but I think I will use it as a pattern.  Apparently, the trim is a much more important find.  LMC Truck doesn't carry the trim.  

What I salvaged from the donor is pretty rusty, so I tried the aluminum foil cleaning method.  It works well on lightly rusted chrome, but I found that the heavier rust was less responsive.

Before and after.

I think it will be good enough to use.  Phase 2 is cutting out a new headliner.

Another Setback

Today I was confident enough to take the truck to work.  That was a mistake.  I drove it around town yesterday (Sunday) without incident and I thought I had resolved the stalling problem.  Nope.  My office is about 15 minutes away.  About 3/4 of the way there it started missing.  I made there alright, but on the way home that evening the missing got worse and it finally stalled again.  I had to tow it back.

I thought that my problem was with fuel.  I noticed that air rushed into the tank whenever I opened the gas cap after it had been running.  A previous owner had replaced the gas tank recently and I assume that it was not properly vented.  Also, a section of the steel fuel line from the tank to the engine had been bypassed with hose.  I figured that because the tank was not venting, after running for a while pressure would build up and the pump could not pull any more gas.  Seems like a plausible explanation   To test my theory, I started driving it with the gas cap off over the weekend.  That worked for a while and I'm still convinced that it was at least part of the problem.

Now I am considering an electrical cause.  When it stalls, it turns over, but never fires.  Fuel is reaching the carb, because I can see the accelerator pumper squirting gas into the carb.  After it sits for a while (hours) it will start again.  There are some sketchy wire spices between the distributor and the coil (not the high voltage wire).  After doing some research, I think I am going to try to solder those together and put heatshrink over them.

I have also noticed a lot of carbon under the distributor cap.  I have heard of carbon tracking, but this is more of an all-over build up.  I will probably replace the cap and rotor, but I would like to know what is causing this.

Carbon under cap.  The dark spot on the left is where I wiped it with my finger.

Carbon on rotor and in distributor.

Parts Pull

Today, I visited the donor truck I found on Craigslist.  The gentleman was very nice.  He insisted on pulling any parts that came from under the truck because he didn't think it was safe.  I got:

Seat belts

The seat belts are a nice addition. Pretty faded, but definitely an upgrade.  I did discover one interesting thing.  I had shoulder belts rolled up under the cover where they attach, but they did not have any buckle on them.  Weird.  I think shoulder belts were an option in '76.

New belt installed

Rear brake line

On the rear of the truck, there is one brake line that comes from the front to the driver's side of the rear axle.  There it splits and one line goes a very short distance to the left wheel; the other line goes all the way across the axle to the right wheel.  My line that goes to the right side was crimped off.

Crimped brake line after removal

I replaced the line with the one from the donor truck, which was in good shape.  But now I'm wonder if I should have waited.  They may have crimped that line off because the wheel cylinder was leaking.  Now I just hooked it back up.  I probably need to rebuild that brake.

Headliner

I got the headliner and chrome trim as well.  Unfortunately, the headliner tore during removal.  I may try to repair it or use it as a pattern to make a new one.  I think I can use the 1/8" pressboard they have at Lowe's.  The chrome is rusted, but I am going to try the aluminum foil trick to clean it.

I passed on these items:

• Weather stripping.  It was in better shape than mine, but not great.  He wanted $20 and I can get a brand new set for $60.
• Door latch posts.  These are $10 brand new.
• Glove box liner.  Again, it was in better shape than mine, but not tempting enough.
• Chrome vent shades.  I actually kind of want these.  I may try to get them later.

Donor

I found a '76 Ranger nearby on Craigslist.  Owner has it listed for $800, but is willing to part out.  I hope to grab the seatbelts and some other items for my Punch List this weekend.  I bet I can get that one brake line I need off the rear.

Donor?

Air & Fuel

I decided to replace fuel lines leading into and out of the fuel filter as there was still some minor leakage there.  I also put an air filter on the truck as there had been none.  The filter housing was in the bed.  Thanks to my son Sam for locating the wingnut back there!

I still did not trust it to go very far, though.  I decided to leave it idling for a while that evening.  After about 15 minutes, it developed a pop (small backfire?) in the passenger side exhaust.  I decided to shut it down.  Pretty discouraged.  Lots of possibilities are running through my mind.  It could need a complete rebuild of the heads.  I hope it is something simple like a coil.

First Weekend

On Friday April 12 it was difficult to concentrate.  I wanted to go home and play with the new truck.  On the way home from work, I bought new plugs and wires and a shift knob (the first thing my wife noticed was that there was no knob).

I installed the knob that night and was able to work on a few things:

• I got the glove compartment open.  It had been stuck, but a little WD40 did the trick. Upon opening it, I discovered that it needs a new liner inside.  The original ones were cardboard, but they make polyurethane replacements that are pretty cheap.
• I got the interior light and cargo light working via the switch above and left of the driver's head. I had never seen that switch before.  The interior dome light still needs a lens cover (cheap).

The next day we had people coming over so I was not able to focus on the truck too much. I spent most of the day getting the yard ready for the party.  I had promised the kids that I would take them around the block (no further because the truck doesn't have shoulder belts).  Unfortunately after several jaunts through the neighborhood, the truck broke down near the house. It was discouraging for sure, but with my neighbor's help (thanks Glenn!) I towed the truck home.  Not sure what the problem is, but it won't start at all.  I suspect the carburetor.

I also started my Punch List.

Sunday I installed the plugs and wires.  The number 4 plug was damaged, so it was likely that something was (bad) wrong in that cylinder.  My brother and his friend Will came over to help (thanks guys!).  I had an old, unreliable compression tester which showed around 70psi on number 4.  We decided to try to start it up anyway.  The plugs and wire helped tremendously.  The truck idles very smoothly.  Too smoothly to have something broken off in cylinder 4.

Damaged spark plug

The day ended on a positive note despite a few worrisome moments.