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'86 Jimmy 4in Lift, 40’s, tons, 8.1 Swap- 700r4 said PNNNNN

This is not a dedicated trail rig, but does trailer to the destination usually. I am currently in the planning phase of doing a 52/56" spring swap, and getting back to being more road worthy.
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Wasn’t able to move the bolts the correct direction, so I just ovaled the holes just a bit. Now it fits nice and snug.

Going to clean surfaces and seal the adapter to the case and let that sit for a day or so as I know these clocking rings are tough to get them sealed.

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Good progress today!

T-case mounted after massaging my Jimmy.

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Went to Manhattan, KS this morning to snag my free “dented” driveshaft from a buddy. Decided to cut it in half, then bolt to each end and cut at the middle ground. Literally, my initial cut is almost exactly the length it needs to be!

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I then decided to finally swap out the front diff cover I won years ago from @CyberSniper

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And hung the old one on a post as a badge of honor.

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Well, I hit a dead end today. Waiting for parts that won’t be here in time for King of the Off Road this weekend. Thankfully I hadn’t registered yet, so no money lost. I’m going to refocus for next week at a more local event called Frostbite. Meeting lots of friends there and should be a good time. Last time I was there I split a PS pump in half, so I need a redemption run from last year.

I have a u-bolt style output yoke coming and a driveshaft that should be ready Friday afternoon. I should be able to top off fluids and test everything out Saturday or Sunday.
 
Good progress again today.

Rear shaft was borrowed from the Green blazer as it’s much smaller diameter and helps with the muffler clearance.

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Got the shaft in and complete minus the rear u bolts.

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Shifter linkage done. 4x4 indicator switch swapped and done. Front shaft is out for the most forward u-joint. Parts should all be in tomorrow. Then to fill up the front diff and t-case.

What’s the best choice for t-case fluid on this 208? I’ve always just ran atf in the past.
 
GWeakland620 said:
Good progress again today.

Rear shaft was borrowed from the Green blazer as it’s much smaller diameter and helps with the muffler clearance.

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Got the shaft in and complete minus the rear u bolts.

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Shifter linkage done. 4x4 indicator switch swapped and done. Front shaft is out for the most forward u-joint. Parts should all be in tomorrow. Then to fill up the front diff and t-case.

What’s the best choice for t-case fluid on this 208? I’ve always just ran atf in the past.
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Atf
 
The hard work paid off! Tested it on the jack stands tonight so I could check u-joint clearance. Everything worked great. Unfortunately found a large fuel leak so no road testing yet.

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Also 24 hours with fluid and run time on the t-case, and not a single leak anywhere.

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Just my 2 cents but if your pinion is pointed straight at you t-case I am thinking you are gonna have a vibration when the pinion rotates up under acceleration. Isn't that how you want it if you are running a CV driveshaft? Pointed straight inline with the driveshaft? I may be confused on this.

Good job on the t-case, they always scare me to do all that work and hope it doesn't leak.
 
Pinion in line for cv shaft, matching angles for non cv shaft, from the video it looks like your angle at the t case is steeper than at the rear, but it may just be the camera angle
 
The camera doesn’t help angle, but it’s not pointed directly at the t-case. It is however less of an angle than the t-case output. They don’t exactly match.
 
I got the truck down on all 4’s this afternoon. Was able to test drive it down the block and back. I immediately noticed the front driveshaft was contacting itself, but in 2wd the truck did fine. Got it up to speed and it felt and sounded so much better.

I spent some time after dinner trimming some fat on the front driveshaft. Ignore the terrible video, but you can see I have full clearance now. I’ll toss it in tomorrow and do some testing to make sure it’s good to go.

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GWeakland620 said:
I am! Lol

My buddy owns Four by Design and we traded some parts for some bumper work. I just need to make the couple hour drive to his place some time.
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Fine I'll let it slide a bit longer.

I'm the opposite, my blazer is out of commission and needs tires and a bunch of work but I'm thinking about building new bumpers cuz I can do it for free at work.
 
max 02 said:
Sick trailer as well! :waytogo:
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It’s overkill, but so nice to have! My brother and I own a 14k bumper pull together, but he uses it for his excavation business all the time. So to make up for it he stores this gooseneck at my house and I can use it whenever. He just comes by and uses it maybe once a month, then brings it right back.
 
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