When I was trying to drop the fuel tank, I broke one of the bolts that holds the fuel tanks straps to the frame. I had no options left. I was thinking about using a dremel, but then I thought dremel + sparks = BANG. I ended up driving 30 miles to borrow a bolt cutter, so I could cut off what was left of the bolt. I have no idea what those things are made of, but it must be some kind of incredible steel that was made to stay there, FOREVER! I could get a good bite with the bolt cutters, but it was so strong that I could only take little 'nips' out of it at a time. One time the bolt cutters ricocheted back and nailed me right in the head. Yeah that one hurt.
Once I got the old one out, I bought a fuel pump for a 1989 turbo caravan, figuring it would be a direct swap in. Nope! They're different.
I took back my $80 fuel pump to autozone. I opted to buy a new fuel pump assembly, since I had connections to NAPA through an internship I was enrolled in at a car carage. I got the whole assembly (for a V-6 caravan) for $150. The price, if I didn't have the connection, would be $260. $110 savings! NICE!
After the pump was in, we fired up the van, took it for a victory drive. Unfortunately, the same thing happened. It just randomly died. After 20 minutes of waiting I was able to limp it back to the house. By now I'm frustrated. $150 and it still doesn't work. Then an idea struck me. It could be the coil! I MUST BE A GENIUS! $18 later, I had a reliable minivan.
One tire fire? One wheel wonder?
Now, I've done more than my fair share of burnouts in this van, especiall when it was still naturally aspirated. We would have burnoffs. Great fun. 
With the winter season coming up, I figured it would be a good time to have the differential rebuilt. I don't want to send the differential pin through the side of the case! That wouldn't be pleasent. So, starting at 6 P.M. on a friday night, I Started taking out the transmission. Sway bar came out nicely. Axles came out pretty easily too. Unbolting the transmission was easy, but taking off the bobble strut/transmission mount/shifter cable bracket wasn't! I finally got it out that night at around 11 pm. The next morning, I awoke at 6 A.M. to make the 100 mile journey to Cliff Ramsdell's house in Enfield, Connecticut (for those that don't know, he's a turbododge legend. He can rebuild/fix ANYTHING). It rained hard the whole way up. Still averaged about 90mph on the highway. Before I went up there, I purchased a new differential pin, spider gears, pinion gears, and pin retainer. Total cost $103. In about an hour and a half, he completed the job. He also installed differential pin retainer clips, so if the differential pin ever decides to take a vactaion, it aint goin' nowhere. Labor, only $60. Good insurance for winter driving.
Broken axle boot?
Duct tape indeed. It has plenty of room to swivel if it wants. It's been this way for 3 weeks and it's still fine :)
I'm messy.
Putting the transmission would have been much easier with a hoist of some sort. My dad and I tried and tried to line it up correctly with a floor jack, but it wasnt cutting it. I ended up lying underneath the van with the transmission on my chest, and lining it up that way. It worked better! When I had everything back together, I was ready to give the van it's maiden voyage with the rebuilt differential. I heard a tinny (is that a word?) rattling noise. I peeked around, and saw that there were marks all aroudn the back of the flywheel, something must have been hitting it! I tightened everything once again and the problem went away.
And now, the story leaves off once again. I have a (hopefully) reliable van that I will use to get towork and school. More to come.
New brake pads went on too.
Dawes Devices dual stage boost controller!
I installed one of these controllers so I could crank up the boost a bit. Since I didn't have wastegate solenoid, I plumbed the wastegate directly into the throttle body vacuum line, giving me about 5 pounds of boost. Fast enough for everyday driving, but not fast enough for me. It was very easy to install, the hardest thing to do was to send the wire into the cab. It even came with a lighted switch that I installed near the radio.
Bad picture, but you get the jist of it.
Another bad picture, but it's where I mounted the boost controller. Two self tapping screws is all it took. I highly suggest it.
Oh. I also finished the exhaust, I sent a 2.5" pipe out the side. I had to reduce it a bit to qualm the boost creep.
Random, but here's better pictures of the interior lights I installed.
In it's element. page one!
Questions or comments? Email me TwoGsInFaggella@cox.net, or talk to me on AOL instant messenger, under MinivanHotRod
