1989 W150 Forest Service truck resto - nickname "Govt Chz" - Stoffregen Motorsports

[Stoffregen Motors]

The fuel pump module on early EFI vehicles can be cumbersome to rebuild. I tried to find a new assembled unit, but could not. This module was not in bad shape, but I do worry about the sturdiness of aging plastic. Luckily, the pump module is not exposed to sun or heat, which can dramatically reduce the lifespan of plastic.

Replacing the pump is only half the battle. Proper fuel hose that is rated for the PSI of TBI EFI, and also rated for modern fuels, is a must. Adhering to my first rule of business - don't kill the customer - I worry about things like fuel and brake hoses.

Once the module was rebuilt, which really only took an hour or so, fitting it into the tank was next. I mentioned cumbersome, this is one area that qualifies as cumbersome. Where does the module fit? Kinda everywhere, but it nestles gently into it's home carefully.

One touch you may notice is the use of "EFI" hose clamps. They are not worm drive or spring clamps. They are a continuous band of stainless with a screw and a nut. This way, they can clamp the hose all the way around without pinching it or cutting into it. If you use the right size clamp, the two ends of the clamp tighten up completely with no gap, so you know the hose is tight.

These two pics show the pump as it came out. Notice the worm drive clamp and the crimp terminals on the wires? I hate both of those...

 

[Stoffregen Motors]

Before final installation of the pump, I took some ohm readings on the fuel level sender. The owner complained of gauges that were not always consistent, so a quick measurement of ohms at full and at empty were taken, and those numbers written on the top of the pump module for reference later while hunting down the gauge issue.

 

[Stoffregen Motors]

These next few pics show some of the small details.

We planned on installing an auxiliary trans cooler, and I really dislike ATF leaks, so I cut the end off the hard lines where they would go into the cooler and fitted some -6 AN compression fittings. I didn't know these fittings existed and happened upon them by dumb luck. If any of you are familar with AN plumbing, there is no AN equivalent to 5/16. Well, there is, but it's -5 AN and only used in military applications and is outdated at that. So finding a fitting that adapts a 5/16 hard line to -6 AN fittings was a game changer. It saved from having to bend up new 3/8 hard lines.





Wiring for the engine and trans needs to be checked and verified, but also cleaned up and re-wrapped. The original wrapping is some kind of fabric and was completely wasted, and there were a few original wire taps that needed re-crimping, but other than that, the engine/trans harness was in decent shape. But man, was it dirty. Life in the forest service means life on dusty, muddy trails, and the harness held at least a pound of grit, which I washed off before inspection and repairs began.

 

[Stoffregen Motors]

Another small detail was the color on the air cleaner housing. We powder coated it to match the valve covers. It's a nice touch, and I may find a vintage "318" sticker to go on the lid...

 

[Stoffregen Motors]

These next pics show a completed chassis, ready for the body installation. I take a lot of pleasure in the rebuild process of the chassis and drivetrain, and covering it up with the body brings mixed feelings.

 

[turkeybird56]

You do such Great work and attention to detail.

 

[Stoffregen Motors]

You do such Great work and attention to detail.

Thank you. All it takes it time and patience.

 

[turkeybird56]

Time I would have. Patience nope only have 15 seconds a day lol.

 

[Stoffregen Motors]

Hi guys. I realized the other day that I never finished this thread. I'll post up a bunch of pics with few words. If anyone has any questions about this restoration, don't be afraid to reach out.

This was my initial attempt at the brake master/booster combo, using an aluminum Corvette master with a 1 inch bore, and a generic hydroboost unit from Power Brake Sales in Sacramento. The brakes were weak and the pedal went to the floor. The rear brakes locked up a lot too.

 

[Magfan2]

An incredible journey! Thanks!

 

[Ritchie_Rich]

Really cool build.

 

[Fatbob Frank]

 

[91rt]

Awesome work man! Hope to see some truck pics with the body and bed on. Looks great so far!