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2001 Durango R/T frame off restore

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2003 build durango frame mounts
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Discussion starter · #81 ·
Engine bay cleaning, Transfer case cleaning
started clearing the rust of the front of the frame in engine bay.

Dirty little 244
first soaking.. nothing
get out the wire brush
I have an ooooooo shiny addiction. Anyways cleaning up the transfer case. It had clay that was baked on the outside. I tried every cleaning solvent I had, except one, in the end only a wire brush would work.
 
Discussion starter · #82 · (Edited)
Engine Bay cleaning and priming

This weeks edition is cleaning more paint/rust off of the front engine bay chassis area and getting it primed. I was really struggling with remove or not removing the brake lines. I have not found a way to activate the CAB controller on the Durango's without using the DRBIII tool. If anyone knows of a way to do this please let me know I didn't want to break the lines until I had to. And because I have not found anyone offering pre-bent lines for the Durango. I can find cheap sets here but the quality is unknown. Using these now, means I need to have the front end swapped to the donor dual piston calipers and steering knuckles. In the end next session I may end up taking all the lines out. I can't do the right side of the frame on the top with all the brake stuff there.

 

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Discussion starter · #83 ·
NV231 D HD transfer case 1999 Durango ( ol' Blue)


In addition I have a 1999 Durango SLT 4x4 that started the whole mess I got into with these vehicles. I have removed it's transfer case and have it ready to go to the shop to get repaired. My father is going to front the money for the repair. I know at least the chain is toast. Point to be made in this series of shots is how a transfer case to transmission mounting area is clear of RTV, the weep hole is relatively clear. Also you can see some fouling ( gray) meaning that one of the two seals is bad. ( my guess was transmission rear seal). Any body interested in purchasing this baby once I fix a couple things let me know.
 
Discussion starter · #85 ·
Brake lines ad Nauseum

I have to get the right side of the chassis wirebrushed and primed ready to be epoxied. Can't do that with all the rusty brake lines all over the place. Before I remove the rest of the lines I wanted to have a plan in place. So I have been sourcing hard lines for the Durango's with RWAL brakes ( all disc or disc/drum). Feel free to follow along.



I purchased an ebay kit for 4-wheel disc/ awal brakes. I knew it would not work, but I wanted them to have a kit that works for the RWAL folks. WHY? you ask? Lets go to the source. I did a chat data request with Chrysler/Jeep: I could only get date for 2003 Durango brakes:


2003 Dodge Durango. 5/13/16
2003 Dodge Durango 4X2 Information
Vehicles with BGJ 4 Wheel Disc, Rear Anti-Lock Brakes - 37,570.
Vehicles with BRT 4 Wheel Disc, Anti-Lock Brakes - 2,723.
2003 Dodge Durango 4X4 Information
Vehicles with BGJ 4 Wheel Disc, Rear Anti-Lock Brakes - 67,687.
Vehicles with BRT 4 Wheel Disc, Anti-Lock Brakes - 11,836.
Thats 105257 people compared to 14559. RWAL folks need a kit.

So I have been in contact with Jeremy at Finelines. They are going to work with me and have me penciled in around June 13th for work. I spent most the day using cardboard to fit the lower lines on to my cardboard frame. I put all the brackets, brassblocks and brackets in the radiator box I had. Neat right. I am still struggling with getting the upper lines to the proportioning valves and master to proportioning valves off with out wrecking them. We'll see. Here is a link to my personal website for some of my vehicles. I have a WAAAAy more extensively described set of pictures of the difference in the lines I received vs those that I need here. Working 7 days, this is all the update I have time for now. Vacation in 9 days woot. I need two. Stay tuned> Is anyone reading this?:shock:


 
Discussion starter · #86 ·
Breaking Bad Brakes

The past two weekends has been put into how to send all my brake parts to sstubes.com to have front hard lines made. There are two versions of lines one for the 2001 and 2003. I took a piece of wood and mounted the 2001 CAB controller directly to the board with the mounting screws
.

I then did the same with the 2003 controller
. Finally I added the mocked up lower left and right assembly with the brass blocks on cardboard
.
After all of this, I then proceeded to add each brake line that I purchased and put cardboard design notes on each one.
this series shows the 2001 CAB controller with its spaghetti monster of lines for the valve and proportioning valves ( I'm sure they have other proper names ). You can see the lines all the way down to where they connect to the top of the two brass blocks that are used in RWAL. ( 4x2 4x4). IN the 3rd and 4th  pix you can see the 2003 controller and lines. Much simpler. Last one is a top view. All of this was shipped out with 1000$ insurance. This is how much the controllers are worth together, not counting the lines. ( $640 and $464).Since my durango is a hodge podge of parts, I need to have both sets of lines. I want to get the truck running with the 2001 ECU and CAB controller, then when I swap bodies, move to 2003 everything, wiring harness, CAB and ECU. So I need both sets of lines. By doing all this prototyping work, I hope that the most common type of gen 1 D's will have brake lines kits available that work out of the box.
 
Discussion starter · #87 ·
Collecting the front end components:

Collecting the front end components:
I have a guy at one of my jobs that built his own powdercoating oven out of oil drum, four heating elements and a dryer timer. I think I am going to have him powder coat the calipers (color?). Anyone know if I can find rebuilding parts? I haven't looked yet. I have already taken the rotors to O'Riley's to get turned on monday. Found one of the hubs totally blown on one steering knuckle. Common issue, going to have to replace em in pairs.



I was goofing around with an old broiler. What do you think, a Durango broiler trailer?
 
Discussion starter · #89 ·
Donor chassis stripping. REPO'in da partz

Here are shots of the final chassis disassembly. Hard to believe I have now taken every system off of a vehicle. Almost to half way point. Axle(s) captured, brake calipers and upper a-arms. I have never taken or messed with the torsion bars/keys etc. yet. Please pass on any advice. I would like the lower a-arms and everything I can save.





This set of 3 pix of for the person asking about removing the axle from the engine. I could not find the thread in my limited time to post. There are the 3 mounting locations on a front axle. All 98-2003 typical. To note is one of the bolts goes through the mount for the starter IIRC.
 
#95 ·
Is there a roll pin holding the torsion bar in? I'm going back 13 years so I might not be at all correct.
 
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Discussion starter · #98 ·
Steering gear clean up.


Here you can see the shots as I progress through cleaning the best steering gear of the two.
I will be wire brushing all the aluminum, then clear coating it, the body probably be black. though I might make it silver too. IDK yet.
 
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