Meet Clifford

[r3dd0g]

All the gears work as expected, as do the ranges in the 208. The trans had what appears to have been gear lube in it. Visually everything looked very good, no debris or anything inside. I'm hoping the synchro's are fine as I really doubt the stuff that was in it was GL-4

I have 5 quarts of Redline Synthetic MT-85 gear oil which is GL-4.

The 208 if memory serves me just uses ATF?

I have been running NV4500s in my off road trucks for quite a while. The first one I built I used a mix of Redline MTL and MT90 (they didn't have the MT85 back then) and it killed my syncros in about a year. I switched to running either the fluid straight from the Dodge dealer, or the Amsoil Synthetic Manual Transmission and Transaxle Gear Lube (75W-90 API GL-4) and I haven't had any issues. I run the same in the transfer case just in case there is cross contamination.

 

[tRustyK5]

Interesting that you had issues even running GL-4 fluids. I had always heard that was the critical thing was the GL-4 part.

Checking the Redline site the MT-85 is rated specifically for the NV4500

MT-85 75W85 GL-4 Gear Oil

Popular replacement for NV4500, Hyundai, Kia, Nissan (Altima, Maxima, Sentra, Versa, 350Z and 370Z) and Mitsubishi Diaqueen fluid (for Eclipse, Lancer, and Evolution models)

www.redlineoil.com

Assuming the synchro's are currently OK, I guess we'll see.

 

[GWeakland620]

Yes ATF Dex3

 

[r3dd0g]

The GM transfer cases aren't picky about what you put in them. I've run ATF, gear oil, and syncromesh. I just put the same thing in everything.

 

[tarussell]

I’m fairly certain that an ‘85 on up square crossmember made for a short-foot mount will work just fine - you could also just stick with your ‘84 and older “flat” crossmember and just add a spacer between it and the mount on the tail housing.

Add another vote of confidence for the 208 case being able to handle a little thicker oil just fine with no bad results - the bearings and planetary gears in a 208 don’t demand such thin oil as ATF.
Some cases can’t handle the thicker viscosity but it’s actually better for the 208’s inards.

 

[tRustyK5]

Spacer sounds good...I do have the stock mount from the 94 and I can take some measurements of the current output and go from there.

 

[tRustyK5]

Got the passenger side rust repair done.

 

[tRustyK5]

Bedside fully installed

 

[max 02]

Perfect weather for getting it done Rene! A bit humid but not hot, not cold.
And so wet out that it’s nice to be indoors.

Looks good!

 

[tRustyK5]

Well, I've been trying to "keep my feet moving" on this. The immediate goal is get the passenger side done so I can move the truck over about two feet and give myself some room to work on the driver's side. I am pretty happy with the floor repair, and now it was time to get the door situation sorted. I have Chinese door shells, and was hopeful they'd be at least tolerable.

First pic is the remains of the OE door. no saving this one...


On the upside, it sure made removing the guts a lot easier.

Next up was getting the new door on, and having my fingers crossed the gaps and general fit would be OK. Then it was going to be installing all the guts, after cleaning, lubing etc the regulator, lock mechanism etc.



I laid out the mirror mount pattern and installed some riv-nuts.





The rubber stuff was also complete garbage, so I took a chance on a full kit off the jungle site. I would give that kit a 8/10. Quality of the seals and sweeps feels top notch. the only complaint it the outer window sweep clips are not perfectly located leaving the sweep sitting 3/16" high. Functional, but dangit China!



Inside done too. Gotta pat myself on the back a little, this door opens and closes so nice it's stupid.



Next up was getting the new fuel tank installed. Not that bad a job and nothing out of the ordinary to report.





I have a couple of small items to cross off the list, then it's on to side two, which should go a lot quicker.