Project VXOverLand

So as it turns out, breaks are fine actually. I was digging through the repair manual and found a page discussing the issue. So, following the manual, I cleaned the rotor with break fluid, started the engine (no idea why this is impoortant, but the book said so), pumped the break a few times, worked the e-break a few times, then, I was supposed to be on a lift and spin the wheel, but since I was on a small incline I just put it in neutral and let it roll back. It did move at first, then I repeated the process while in neutral. About the second actuation of the e-brake, the caliper popped free and the VX started to roll down hill. I stopped it (with the break), put it back in park and did the entire procress (including more break cleaner) three more times. Breaks are working fine now.

So relieved! That saved me almost $100.

While I did confirm the breaks works normally now, I still have an unidentified groan. I am fairly certain it is the transmission. When I got the VX, it was nearly completely out of fluid. I am thinking that after my little test drive, it pulled more fluid into the internals and i may be low on fluid again.

The groan only happens when applying power to the VX, and while in gear. Groan increases with petal travel, even if I am stopped and holding the break. I think this weekend (it is not yet a daily driver, to many issues still), I will check the fluid again.

Just got an email from isuzupartscenter.com, which is actually Jack Miller Kia Isuzu out of North Kansas City, Missouri, they processed my order for window trim! $70.92 for part #0972217290 - Seal; Waist, Front. That's a bit 'o chash for what seems like a minor piece, but I need to get this project done right.

A couple of posts back I mentioned a door handle clip being broken. I could order one of those as well, but I really don't to spend $45 on a plastic clip that is a bit larger than a nickel. I still have the original (minus one tab) and I have found a website that can 3D print custom items, even one-off's. Now I just need to learn google sketchup to create the file they will need. I have also heard rumors that my local library (brand new and opens in a month or so) will also have 3D printers for use, so I may wait a while and see if that turn out to be true before ordering online.

I also ordered an OBD2 reader from amazon that uses an app and Bluetooth. It says it can reset check engine lights and read everything. I installed the app, it asked for a vehicle vin and downloaded all of the OEM codes for the VX! Once I get the reader I will let you know how well it works, if it works.

check and see if they can 3/d print you spare cover knobs too. ;)

For the door locks?

no, for the hatch.

I dont have those or the hatch cover for the inside. I am sure they could though if you could get an appropriate 3D file.

The website is: https://www.shapeways.com

I hit them up on Facebook about automotive interior trim pieces and small plastic bits and they said it shouldn't be a problem. Basically they can print anything, some even out of metal, though I think that would be very expensive. I don't have any prices yet, they need the 3D model file before they can give a quote.

Checked the transmission fluid again, no leaks! Yay!

The VX seems to be running OK. I am getting a couple of OBD codes that I am trying o sort out. Intake temp sensor and EGR recirculation temp. Looking though the manual they charge a common ground so I will clean both sensors and check the wiring before changing parts.

I am also getting a strange "wuring" noise from the engine. Not sure if it is the fan, or if the intake is sucking air, or if I have an exhaust leak, or if that's normal. Just haven't tracked everything down yet.

Conducted first real "test drive" today. Total distance around 25 miles, speeds to 60mph, mix of back roads and in town traffic. Also did grocery shopping. This was mainly to get a feel for how the VX drives, and to try to learn the VX, and I learned a lot. I learned the steering is a bit on the sloppy side, could probably do with an alignment, steering wheel is "centered" when driving strait, and the cargo area is far smaller than I had originally thought. However, the engine stayed cool, the AC worked well (though a lot of condensation), the transmission (which I was worried about) performed flawlessly, and I learned it is a lot of fun to drive. I calling this one a win.

Cargo area only "looks" small. That's because the back seats are exceptionally roomy for a vehicle this size. Then you fold them flat to the front seats, and find you can fit 4 full-size tires in the back end. :)

Took the front bumper and grill off today. The "tube" that I assume is the actual bumper in nearly rusted though on the drivers side. I guess that is a perfect excuse to build my winch mount ;)

I also removed the headlight housings to clean and polish them. I am using the "Rustoleum Wipe New" head light kit. I must say this stuff is amazing! I have the final coat "curing" on the back porch now. I will post comparison pics when I get installed tomorrow. The reason I am not installing today is the instructions say to keep it was from moisture for 24 hours, even dew. Where I am in Georgia morning dew looks like a rain storm came through over night this time of year.

Also, how do you test ball joints?

Got the head light pods reinstalled.

Here is what it used to look like: http://imgur.com/x45xv2M.jpg

Here is what it looks like now:
http://imgur.com/kF5ndOJ.jpg
http://imgur.com/0VIV8wr.jpg
http://imgur.com/MKJDBoJ.jpg

And reinstalled:
http://imgur.com/918tegl.jpg

Took some serious elbow grease, but I "got-er-dunn" hahaha

If you're talking about the ball joints on the control arms, what I usually do is jack up the frame so the wheel is off the ground, then try moving it. If it moves on yaw axis, you probably have a tie-rod issue. if it moves on the roll axis (top/bottom), you probably have a ball joint issue.

Put some Mother's back to black or something on that trim. ;)

One thing at a time. I have a lot to do in order to get this VX right again. It is worse shape than I thought, but the price was right so I didn't expect perfection anyway. ;)

More progress today.

Got rid of all the engines codes except the P0405 (EGR Low) error. I pulled the EGR sensor, new gasket, cleaned it out really good. It seemed to move freely, but at over 170k miles it probably needs a new one. Before I did all that, the error would come back in 3-5 seconds. After all that, and idling for 20 minutes it would take up to 15 seconds to come back, and after a quick 15 mile drive down a back highway it now takes nearly 30 seconds to come back. I am not sure if the gasket is "seating" itself, or if the damn thing just needs changed out. Probably the latter. It looks fairly rough. I'll let the engine cool down for a while then check it again.

My other issue was the Air Intake Temp sensor (P0113 I think). Solved that fairly quickly. Cleaned the plug and re-inserted. That one was easy. As soon as I did it though, the air intake throttle control thing (cant remember the exact name at the moment, but it has the two small torque screws), decided it wanted to make the engine start and idle at 2600 RPM. That was a PITA to diagnose.

Once I figured out what it was it was just a simple matter of removing it, give it (and the housing) a good thorough cleaning and reinstall. This VX is becoming quite the little problem child! LOL! But, that tends to happens when they haven't been treated right for a long time. Oh well. It's late July in Georgia and hot as all get out. I think I am done working on it for today .... nahhhhh ....

Finally got around to doing the transfer case fluid, yay! More progress! Like the transmission the fluid was a burnt brown color. New fluid should help it along.

I also changed the transmission drain plug gasket back to a copper crush washer. I tried one of those cool bolts with the rubber around the base, it leaked. No issues with the crush washers, even if I have to change them every time I remove the bolt.

Also got the windshield washers working, sort of. More than a few leaks are present. I think I am just going to have to swap out all of the old lines. Even the washer fluid reservoir leaked. Add that to my to-do list. Sighhhh ...

I have also identified my groaning noise. Apparently it is coming from 1 or both differentials. I was planning a fluid change anyway, so that will probably be next. Still need to the engine oil and spark plugs, belt, should probably do the timing belt at some point.

Anyway, progress continues....

Purchased new praise pads for the rear however I don't have a garage, just a car port. Storms are preventing further work on the VX today.

[EDIT]

I bled the rear brakes just for giggles sake. Turns out the rear brakes work now. I still need to change the pads out, but it isn't such a rush job anymore.

[/EDIT]

Got the hardware hit for the brakes on order (the little clips).

Installed a universal battery bracket.

Feels good to see items on the TODO list getting green text. Breaking the tasks down from "Completely Fix Everything!" To smaller tasks helps me stay focused and gives me a sense that I am actually accomplishing something.

Yep, i know how that feels. Keep up the good work!

Got the rest of my brake parts in today. Also, the parts I ordered from Japan back on the 13th came in as well! Yay! It's going to be a fun weekend.

First attempt at installing the OEM weather trim failed. All of my clips broke so I attempted, and failed, to repair them. Such a pain in the @$$ this thing is. Now I need to find those stupid clips, or come up with a different solution to hold it in place. The good news I finally have all of the parts I need for the rear brakes. Next Sunday I start a 19 day vacation, so that'll be fun ...

Got the clips (see above) on order, hopefully they wont take too long to ship. This weekend is brakes, engine oil, front and rear diff fluid, grease u-joints, and I still need to track down a vacuum leak that I have been unable to locate.

I think I found the cause of my EGR valve code. There is a large hose that goes from the brake booster to the top of the engine with a one-way check valve embedded inside. The air is supposed to flow freely, but it makes a "noise" when I blow through it and it seems restricted. The valve is working in the other direction, stopping back air flow as it should. I will try to clean it out later in the week, maybe tomorrow if I have time, before I buy I new one.

Today I tried the last possible fix for my error code 0405, cleaning the piping that runs both directions from the EGR valve. No luck, code still comes back. Time to get a new one. Damn it.

As the VX gets more and ready for daily use, I am starting to get rid of my other 4x4, a 2013, Toyota Tacoma. First thing to go is the camper shell as it doesn't really change the value of the truck at all and I get a better return by selling it separately. That money will go into the VX and will be more than enough to get her ready to take over as my daily driver.

New head unit finally shipped! Sat in "pending" status for over a week. Still waiting on waist seal clips to arrive. I start 19 days of vacation on Monday, I plan to start the work on the breaks then.

Head unit and speakers installed today! Just need to finalize the mount in the dash as the unit is just a tad too large.

Head Unit: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

Front Speakers: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

Amazingly enough, for the price, it sounds ... well ... amazing. The Bluetooth works well, and receiver picks up more stations than my JBL in my Tacoma. Less than $40 and I have tunes again!

Hope they last for you. My experience with the cheaper end of speakers is that they usually don't last very long. Even without "Stereo Abuse", the ambient conditions don't do wonders for the materials used in their construction.

That is a pain in the butt to do, for sure. I have my spare one soaking right now so that the job won't be as hard this time around.

Worked on the rear brakes yesterday, and of course, new issues were found. Got the passenger side brake pads changed out easy enough. Drivers side was missing a lug nut when I purchased the VX so I popped into the auto parts store and got a replacement. However, after I took the wheel off, I noticed the lug was just destroyed. Threads were all sorts of chewed up. No problem (I thought), just pop it out and replace it. The new lug is being a rear PITA to get re-seated properly, and being Georgia, it decided just dump all sort of rain and bad weather on me. (My next house WILL have a garage) I would finish it up today, but I am heading out of town until Tuesday and yes, I am still waiting waiting for my weather strip clips to arrive.

While working on the rear brakes I discovered a bad lug stud. After breaking 2 replacements, I finally got a new one to seat correctly. PRO TIP: Grease your spacer washers LOL!

Also completed the rear brake work today! Yay! The VX stops MUCH better now. Whew ... that was WAY more work than it needed to be.

As it turns out, there is a wear bar that scratches the rotor when the pads become too thin. The last person to work on the brakes used these as clips to hold the pad to the mounting clips. It was keeping the pads from moving. I put on the new pads anyway, and properly this time.

Seriously, 99% of the problems with my VX are a lack of doing things right the first time. I am fixing so many things that shouldn't even be an issue! Arrrrrgggg! It is ... frustrating to say the least.

Unfortunately, that's a standard feature of many used cars. ^ Glad to see you're reviving it. :)

I am still getting grinding/grating noise out of something in the front axle. I have yet to track that down, could be a stuck caliper, low diff fluid, or even a wheel bearing. Both wheels seem to act the same and it doesn't pull to one side or the other, though it does need an alignment. At this point I am thinking (hoping) diff fluid needs to be changed out.

I was at Walmart today with my better half and picked up a new radio antenna. It's more ... floppy ... than the OEM antenna, but still looks good and is a good match for what it replaced. At only $9 I am not complaining.

I ended up buying a VW antenna off a member here a while back. I'd have given you my old one if I'd known you needed one. :p

Work on the VX has slowed as I wait for parts to arrive. :o Still waiting for my window seal clips.

Also, after inspecting the front end for a grating/grinding noise that I wasn't able to track down, I found both outer CV boots split wide open. I have two half axles on order and I will change out the front brake pads, inspect the calipers, and inspect the outer wheel bearings on both sides. The brakes, maybe bearings, maybe rotors, will be next weekend.

The axle shafts I ordered: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

In case you haven't seen it, member Kenny wrote up a great front bearing re-pack how-to a few years back:

http://www.vehicross.info/showthread...fun?highlight=

I've used this to re-pack my front bearing a couple of times now. Very helpful.

Thanks for the link, it helped a lot!

Today was a good day. New front brakes. Fixed sticking caliper, needed the guid bolt re-greased. Repacked the bearings since they were all in good shape. Replaced both front axle halfs! Yay me! The last part was both and harder and easier than expected. Harder in that the axles didn't want to come out, easier in that I learned there is less to it than I thought.

Need to update my signature again LOL!

Yay! My window clips came in today! One more task to turn green!