The cause


Plenum after removal

New chain


Mostly back together

 

And another thing...

With updates for fuel injection and electronic control of the powertrain, and NAFTA and assembly south of the border and international markets and global suppliers and the year 2000, I expected metric hardware and fittings. Nope! I spent the better part of the first two days going back and forth to my toolboxes fetching wrenches that were either too small or too big before I realized that the damn thing has American fittings.

 

Yeah, driveline is mostly SAE, the rest of the truck is metric...... I never really understood that either.

 

Took the truckster to a local independent shop on June 13 for freon recharge and front-end alignment. I had talked to them earlier about my intention to replace the busted dash pad and if I should have the AC fixed first. "Yes, because if the evaporator needs to be replaced, we have to remove the dash anyway." Short of mechanics/technicians so it was a couple of days before it could be looked at. I was called on the 15th with an estimate that included a new evaporator and dryer; I told them "while you're at it," replace the heater core too.

They called June 20, "bring us your dash pad." Since the dash assembly was out, I figured they are going to put it in as the dash is re-assembled. Tech called this morning, June 24, to say I have the wrong part, I need the glue-on cover. "Nope, the old broken cover is in the bed and I brought you a new pad." I got the receipt, printed pages from the LMC catalog showing the glue-ons and the new dash pad, made copies of of the emails I wrote to LMC to verify what I wanted to order and headed for the shop where I had a discussion with the tech.

Upon returning home, I called LMC and politely vented my frustration. I went back to the shop and talked to the tech who had prepared the estimate. He said I did have the correct part, but didn't think there was enough of the underlying structure to attach the pad to.
"I understand your reluctance to risk damaging a customer-supplied part and having to eat the cost. If you feel confident that you can install it without much problem, fine. If you don't want to risk it, re-assemble the dash without the pad and I will get my neighbor who I have already lined up to do it."

That's where it stands now. Pics of old evaporator and heater core with its cut & hosed lines attached.



Leaves blocking evaporator

"Hosed" heater core lines. No wonder they wiggled around. But it wasn't leaking.

Parts piled in bed, along with new dash pad.

Dash assembly.

 

The garage called today around lunch time, "your truck is ready."

The evaporator, accumulator, dryer and a seal kit was installed along with a new heater core and the system recharged; HeaterTreater blend door coupling installed. Gets cold now, though it seems to take longer to cool cabin than either of our cars, and it was partly cloudy 82 with a 5 mph breeze. Another 'quirks" of these vehicles???

Front-end alignment done; roads so crappy between the shop and my place that I couldn't check for tracking or if it made any difference in steering feel.

Dash pad was not installed. Project to be done with my neighbor in the near future.

Next: headlights. And "while I'm at it", new headlight assemblies for the wife's car.

 

New housings, bulbs, and the heavy duty headlight harness from LMC Truck, or Geno's Garage. Makes BIG difference in headlight performance.

 

Not compared to a retrofit.

 

I'm assuming that a retrofit is something like using Dodge sport headlight housings with a relay harness setup to allow all headlight bulbs to burn on low and high beam or something else?

 

Alienicon, I'm with you. My 2001 Ram 1500 just finally gave out - or at least reached a point where I can no longer do repairs myself, and can't find anyone to do them for me - but before hand, there wasn't really any point where I'd have stopped trying to keep it going, maintained, performing at her best.
The way I see it is that it's still less expensive to repair the truck I have than to buy another used vehicle not knowing what issues it may end up having, and starting all over with the frustration that brings, plus I couldn't possibly afford a new vehicle, so...
But, with something being a "spare" truck, I don't know if my answer would be the same. I guess joetruckster could look at it as an investment. If/when he should decide to sell or trade the spare truck off, whatever he put into repairs increases its value, as opposed to trying to sell or trade it off with the repairs being necessary.

 

No "new" trucks have the looks of a second gen(that's why i have two!), So it may be newer and it will be uglier. Keep the second gens on the road!
A "retrofit" is where you get clear lens housing and install "modern day" projection LED, HID or other bulbs in. With 20+ year old vehicles the aftermarket has long forgotten about them so you have build them yourself. Also can install halo's and other options.
https://www.theretrofitsource.com/bi...p-upgrade.html

Here is a video of the process but i wouldn't use JB weld there are other means of doing it. Plenty of other videos on the subject.