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-   -   1977 Jeep 401 Wagoneer (Wedding Wagon) (http://www.ifsja.org/forums/vb/showthread.php?t=186540)

Wagoneer Taylor 01-02-2019 03:45 PM

1977 Jeep 401 Wagoneer (Wedding Wagon)
 
Hey all,
Finally getting around to posting my Wagoneer build.
The plan is to build a Weekend Warrior, that could be a daily if desired. Not a true rock climber but something we could take on trails. Its a Jeep after all!

Here's the back story (this may not be quick :rolleyes: ).
I got this Wagon for free from a co-worker, it had sat for 2 years untouched in their lawn (as seen in the pictures). I got it roughly 3 months before my now wife and I were getting married (wedding date 09/23/2018). The plan was to get it ready enough to drive away in. (Spoiler Alert---> We succeeded!)
It currently has a AMC 360 (this was a 401 Wagon), I believe Dana 44 axles, original trans case, but external hub lockers.

I'll post over the next few days what we had to do to it to get it driving/presentable to have in our wedding. Then continue as we make it the afore mentioned Weekend Warrior. 401 swap, fixing rusted floors, and sprucing the whole thing up.




Here We Go!

Wagoneer Taylor 01-03-2019 09:55 AM

I couldn't get it to run in their lawn, so here is the first pictures of it at home. (Yes it is sitting in MY lawn now) First thing I did was pull all the spark plugs and shoot a bit of WD40 into the cylinders to loosen them up before I tried to start it. I knew the gas left in the tank was probably bad so I just wanted to see if it would turn over and fire with starting fluid. To my surprise, with a good battery it did! Second picture shows my engine bay, you'll notice the aftermarket distributor, this gave me some grief recently due to the rats nest of wiring the previous owner left me. (That story to come later)



Wagoneer Taylor 01-03-2019 10:15 AM

Now that I knew it would run, I tackled the fuel system, with lack of time in my favor I decided to just "shotgun" the system and go with mostly new parts. I ordered a new fuel tank (a plastic model), fuel pick up tube, fuel pump (which ended up being wrong), fuel filter, fuel sending unit, and fuel hoses. Picture below shows my old tank which was full of a sludgy varnish. I pulled the hard fuel lines too and sprayed and blew them out to re-use.
I apologize I don't have more pictures I wasn't thinking of a forum when I was on this schedule.
I got all these parts off of RockAuto, I know some people don't like this site but I have had good luck with them. Other then the fuel pump which was the completely wrong unit. I will pose the question, Do older or newer 360 engines have a different mechanical fuel pump? This Wagon has a donor 360 and I had to take my old pump to NAPA and they searched and searched for the replacement, finally found it. But it was a hassle, we tried old 360s and Chrysler 360s, they finally just had to search through their catalog and match the description.
After the new fuel system was in (which I did all from the ground under the Jeep with no lift) :banghead: the engine honestly ran beautifully and still does. I took it for its first test drive, after checking the brakes worked. I have a video of this but don't know how to post it??

rang-a-stang 01-03-2019 01:00 PM

I love Rock Auto! I have put the owner's kids through college with all the money I have spent there.

Not sure about the fuel pump question. This thing is going to be awesome!

What's next? Cooling system?

Wagoneer Taylor 01-03-2019 06:00 PM

I have spent more money at Rock Auto then I care to admit.

You are exactly right rang-a-stang, the cooling system was next.
I had preemptively ordered all new cooling system hoses, since it had all sat for 2 years and who knows when they replaced them before that. Crazy part was it would drive around and idle perfect, no over heating. At that point I had done everything but the radiator... now I'll mention again I was trying to build this quickly to use at our wedding, so i thought "well it works now and i only need it to work for one day, I'll really dive in after the wedding"... That thinking was a mistake, at highway speeds it would eventually over come the ability of that tired old radiator and it would overheat. There was some trouble shooting in between but long story short i was overnighting a radiator off amazon the Thursday before a Sunday wedding :banghead: I installed it that Saturday and tested it that night.

I unfortunately don't have a picture of the engine bay currently with new radiator but I'll get one soon.

Wagoneer Taylor 01-03-2019 06:10 PM

In between the fuel system and the cooling system, my girl and I had to deal with the interior looking the way it does in the pictures below...





Wagoneer Taylor 01-03-2019 06:15 PM

So we gutted it!

Don't worry y'all it will all go back together eventually.



I will get some more pictures together and post what we did to treat the inside in the next couple days.

rang-a-stang 01-03-2019 06:16 PM

You have dual gun racks. Respect.

Your shift knob is AMAZING!

Wagoneer Taylor 01-04-2019 09:30 AM

Thanks! I did take the gun racks out, we mounted them to the garage wall and use them as extension cord hooks.

Isn't that shift knob cool! Do you guys know how they are normally attached?
I'd like to take it off and re-finish it.

SJTD 01-04-2019 09:47 AM

Idunno about yours but my '84 just had splines so the end was just pressed on.

Wagoneer Taylor 01-07-2019 06:40 PM

As you can see we found some rust in the floor. I have not yet done it but will be cutting it out an patching in panels. Only 4 spots, driver and passenger sides by the front and rear door drains.

Next was wire brushing the whole inside and spraying it with rust reformer to get rid of any surface rust on the floor, tail gate, and roof. Pictures to follow.

Wagoneer Taylor 01-08-2019 10:07 AM

Heres the bed, and roof after the rust reformer.




Wagoneer Taylor 01-08-2019 10:17 AM

Picked up some Wagon Wheels and Rear Wind Deflector at a junk yard! Plus all the stainless trim I was missing!
If you guys ever need the trim clips that hold the trim to the side of the car I found a decent source (www.autofastco.net) Under GM trim clips I believe. This is for the stainless trim up to 83 I think.



joe 01-08-2019 10:49 AM

77 huh? In your pre-wedding maint I highly recommend you include a complete brake fluid flush/change out.

Wagoneer Taylor 01-08-2019 04:22 PM

Yes sir, 77.

That is the very next thing i did, the overheating problem actually came about from my trip to the offroad place i had do my breaks and lockers.
The hubs and lockers were so fused together with rust i had to have them do it or i would have myself. (also time being a factor)
Did new brake rotors, pads, fluid, and brake lines. Rear drums actually looked good enough to clean up, bleed, and reuse.
Here is the new locker ends.

asphaltrockdweller 01-08-2019 06:05 PM

was perusing craigslist today and found this. Kinda far from you, but a 401 non the less.

https://inlandempire.craigslist.org/...785105774.html

Wagoneer Taylor 01-08-2019 06:08 PM

Quote:

Originally Posted by asphaltrockdweller
was perusing craigslist today and found this. Kinda far from you, but a 401 non the less.

https://inlandempire.craigslist.org/...785105774.html


I already found a 401, just picked it up on Saturday. Thanks so much for looking out!

Got mine for a litter cheaper but was rebuilt back in 2000, but it is complete with all accessories and ready to drop in.

rang-a-stang 01-08-2019 06:21 PM

Quote:

Originally Posted by asphaltrockdweller
was perusing craigslist today and found this. Kinda far from you, but a 401 non the less.

https://inlandempire.craigslist.org/...785105774.html

WHAT?!?!?!? That's a STEAL!!! Holy cats!

Wagoneer Taylor 01-08-2019 06:49 PM

Haha thats alot of new parts for the price!

Still you'd end up nickel and diming the rest of the engine.

rang-a-stang 01-08-2019 07:04 PM

I spent $1000 in machine work for the bottoms end alone, plus $550 for pistons. That

Wagoneer Taylor 01-09-2019 12:06 PM

Found more pictures of the interior disassemble and before and after.

There's my girl hard at work!

Here's a good shot of how much surface rust we got off of the roof and floor.

Before:

Painting with rust reformer:

And After:

Wagoneer Taylor 01-09-2019 12:15 PM

In an attempt to keep water out of the inside of the Wagon I re-did all window seals (quick note when you buy the set they all go in SPECIFIC spot). They look like a seal with 4 press clips but let me tell you each inner and outer have a certain window they go on! I also did the inner and outer seals for the rear windshield as well as what i call the "guide seal" the one the keeps the window on track and seals the top.
New Seals:


The door seals are good enough for now i will do them after i paint it (who knows when that will be) but i have many other things to work on.

Wagoneer Taylor 01-09-2019 02:19 PM

Does anyone know of a thread on here about the vacuum actuator for the 4WD?
I searched for a long time but didn't find anything.
I am mostly looking for a replacement since mine is bad, I have seen some mechanical replacements that are a steel line that actuates it instead of vacuum. But they are for CJs of similar years. Does anyone know of these working for Wagons?

rang-a-stang 01-09-2019 03:37 PM

They are getting tough to find. I paid $80 for a NOS one last year on ebay. If you put up a wanted ad in the classifieds here you might get some folks with some extra ones. Are you sure yours is bad or are you looking for troubleshooting advice, too?

Here's a thread I had with some good info in it.
http://www.ifsja.org/forums/vb/showthread.php?t=184133
The service manual has some good info on it, too. Have you downloaded a service manual yet (they are free, here: http://oljeep.com/edge_parts_man.html)? It really is a good manual.

I am not sure if the CJ actuators would fit but assume they might. I think there is a subtle difference between the CJ and FSJ QT cases but could be wrong.

Wagoneer Taylor 01-09-2019 06:05 PM

Holy Cow that Tom Collins Site is amazing that is some of the best stuff i have seen! I learned more in just the last couple minutes then I have in hours on the web!
Also your thread helped too, sounds like a cable option may work. They make one for the CJ i may just have commit and try it. Or check it out and build my own...
I have no problem with using the vacuum system, a cable may just be more reliable. Also mine is shot it does not hold vacuum in any direction.

Thanks!

Wagoneer Taylor 01-10-2019 06:14 PM

Heres the dash torn apart to see what I need then put back together.
I found an ashtray and bezel out of a black dash Wagon at the junk yard. Have plans to buy a Retro Sound radio, it looks stock but has Bluetooth and AUX plug in hidden in the glove compartment. But this is how it will look for the wedding.

Side note, the blank off plate where the factory clock would be is just painted cardboard to fill the hole. Dont tell the wife :thumbsup:

Wagoneer Taylor 01-10-2019 06:19 PM

With the interior as good as its going to get for now, i installed the new carpet. I only got the front two sections ( i have planes for the rear trunk area ;) ) so it will stay matte black back there for now.

Painted the front grill black as well, bad picture sorry.

rang-a-stang 01-11-2019 12:25 PM

Quote:

Originally Posted by Wagoneer Taylor
...Side note, the blank off plate where the factory clock would be is just painted cardboard to fill the hole. Dont tell the wife :thumbsup: ...

I have a spare analog clock that does not work, if you want it for shipping. Might look a little better in there...? Not that the carboard is bad, just a clock looks nice, too.

Your carpet looks amazing! What kind did you get?

Wagoneer Taylor 01-11-2019 01:43 PM

That would be awesome Rang! Ive been looking for a factory clock. Ill PM you.

Thanks, I got the carpet from our favorite Rockauto! They us ACC which is pretty good. I have gotten several carpets from them and they have all been good.

Wagoneer Taylor 01-14-2019 06:14 PM

At that point the Wagon was as good as I was going to get it before the wedding, I had got it running and driving and looking as good as it could is the 3 months I had.
I had tackled re-doing the whole fuel system, cooling system, trouble shooting the distributor, and carb. That was just the engine.
We stripped out the entire inside of the vehicle and re-did what we could to make it look presentable. Sourcing parts like a rear bumper, dash pieces, wheels, and trim (SO MANY TRIM PIECES!)
Over all we were very happy with it and loved working on it together. (this is the first car I have gotten the wife to work on with me.) We are not even close to done with it and in trying to get it ready for the wedding found how much will need to be gone through.
Here it is the week before the wedding, i took it to work to show some friends (at this point it still overheated, i ordered the radiator that night and installed it the day before the wedding).

Here's the Wedding Wagon on the day of!


I can post more pictures of it on the day if you guys want to see it, but they are all pretty sappy :thumbsup:

Wagoneer Taylor 01-14-2019 06:19 PM

We are still working on it so I will pick up from here as to what we do. I am sure I missed some things trying to remember it all, so I will be more diligent from now on.

And thus begins the next stage of the Wedding Wagon, which will be the 401 install! (and maybe I'll fix some rust along the way) :p

401 Teaser!

Driftwood 01-15-2019 08:21 AM

Your efforts make me want to do more work on my 79! I have similar issues....floor rust, engine "Ticking", etc. etc.

What are your plans for the 360? I REALLY need non-AC alternator mounting hardware.

Congratulations on your recent wedding!

I'm subscribed!

Driftwood 01-15-2019 08:31 AM

I serviced my fuel system. PM me if you need advice. I didn't replace the tank. The PO drilled a 1/2 inch hole into it, so I sealed the hole with 2 part epoxy.
I also replaced ALL fuel lines. There are many and in various sizes. Here's a link.... Removed my QuadraTrac and fuel tank

Quote:

Originally Posted by Wagoneer Taylor


Driftwood 01-15-2019 08:34 AM

Rockauto sells carpet! I will place a order soon!

Quote:

Originally Posted by Wagoneer Taylor
With the interior as good as its going to get for now, i installed the new carpet. I only got the front two sections ( i have planes for the rear trunk area ;) ) so it will stay matte black back there for now.



Driftwood 01-15-2019 08:43 AM

I replaced my vacuum actuator. It requires the removal of the QuadraTrac transfer case. Keep in mind if yours is the QuadraTrac, which I'm certain it is, you are full time 4wd. The actuator, when pulled, places the QuadraTrac into Emergency Drive.
I was surprised to learn that max speed in E-Drive is only 20 mph. Thats in accordance with the Tech Service Manual.

Pics here......QuadraTrac BW1339 pictures. PM me if you have questions.




Quote:

Originally Posted by Wagoneer Taylor
Does anyone know of a thread on here about the vacuum actuator for the 4WD?
I searched for a long time but didn't find anything.
I am mostly looking for a replacement since mine is bad, I have seen some mechanical replacements that are a steel line that actuates it instead of vacuum. But they are for CJs of similar years. Does anyone know of these working for Wagons?


Wagoneer Taylor 01-15-2019 12:23 PM

Quote:

Originally Posted by Driftwood
Your efforts make me want to do more work on my 79! I have similar issues....floor rust, engine "Ticking", etc. etc.

What are your plans for the 360? I REALLY need non-AC alternator mounting hardware.

Congratulations on your recent wedding!

I'm subscribed!


Thanks! Your 79 looks amazing i would never guess it has rust. These FSJs seem to though.

My plan for the 360 was to sell it once its out, you can have the mounting brackets when i pull it though, (as long as i dont need them for the 401 ill have to check) It wont be for a while though.

Wagoneer Taylor 01-15-2019 12:25 PM

Quote:

Originally Posted by Driftwood
I serviced my fuel system. PM me if you need advice. I didn't replace the tank. The PO drilled a 1/2 inch hole into it, so I sealed the hole with 2 part epoxy.
I also replaced ALL fuel lines. There are many and in various sizes. Here's a link.... Removed my QuadraTrac and fuel tank


I already did the fuel system but thanks for the support! I will check out your link to see if i want to change anything.

Wagoneer Taylor 01-15-2019 12:29 PM

Quote:

Originally Posted by Driftwood
I replaced my vacuum actuator. It requires the removal of the QuadraTrac transfer case. Keep in mind if yours is the QuadraTrac, which I'm certain it is, you are full time 4wd. The actuator, when pulled, places the QuadraTrac into Emergency Drive.
I was surprised to learn that max speed in E-Drive is only 20 mph. Thats in accordance with the Tech Service Manual.

Pics here......QuadraTrac BW1339 pictures. PM me if you have questions.


I need to investigate my system further, the vacuum lines are all disconnected currently. I have external locking hubs, does this nullify the all time 4WD?

Driftwood 01-15-2019 12:41 PM

Quote:

Originally Posted by Wagoneer Taylor
I need to investigate my system further, the vacuum lines are all disconnected currently. I have external locking hubs, does this nullify the all time 4WD?


Yes / No

Unlocking the hubs disengages the wheel hub assembly from the splined axles. This allows the front tires spin freely. Voila...2WD

BUT!

Even with the locking hubs unlocked, your transfer case is still doing its thing. It is still turning the front driveline, front differential, and both front axles.

I don't understand why Jeep drivers install locking hubs on this type of Borg Warner Quadratrak 4wd system. :o

rang-a-stang 01-15-2019 12:45 PM

When you buy the QT Part time kit, it comes with locking hubs. So someone may have installed a PT kit in the past. Easy way to check: Unlock the front hubs, put the truck in park/lock the e-brake, lay under your truck and spin the front drive shaft. If you can turn it by hand, you either have a completely toasted QT or a part time kit (my money would be on the PT kit).


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