My progress thread rehabbing this old workhorse.

Day 1... Starts OK, major exhaust leak, would not warm start without a fight.... but I had a theory and so I took a chance for $500.


Good 7ft bed (gate hinge needed welding)... if nothing else it would be a good parts truck.


Interior intact, reasonably clean, and not smelly.


3.0 V6 and working AC as a bonus. (pic taken later)


The leak. Blown out exhaust gasket and rusted out manifold. Head good.


"Day 2" (a few evenings of PB soaks and day of work) All the bolts came out... but this one needed some persuasion.


New manifold, bolts, plugs, and wires.


Hard warm start was temp sensor, as I suspected.


First drive after fixes. Still kinda loud from rusted muffler. (Battery light is loose connection)


Day 3 (today) - Bed off, frame is confirmed good.


Bad shackles


Even worse brackets


Bracket rivets ground off, shackle bolts cut, and one smack with a hammer


Back brackets removed and rivets punched


Shocks while I'm in there


Drill ream bushing rubber and press out seized bolt and collar


All done for the day. Friday: bolt up rear brackets, remove tank and start on front brackets.

 

Great work, and nice job with the pictures!

 

Day 4... It's back on 4 wheels and driving.


New brackets, shackles, bushings, bolts, shocks, fuel pump and rust-stop under, on, and around the new parts.


Day 5: Install the new exhaust and paint it, then rust-stop some more of the frame.


Images...


Bypassed fuel pump relay to drain tank


"1/2 tank" (17 gal), got about 12 gallons out.


Old pump out, new pump ready to go.


New bushings pounded into the back of the springs


Front passenger side bracket and bushing put up one hell of a fight... driver's was easy after the tank was moved.

Bracket mounting areas treated with rust-stop


Almost done for the day... new brackets, shackles, bushings, fuel pump, and shocks... back on its wheels. Torqued up the bushing bolts and took it for a test drive. Day 5 - Exhaust and more rust-stop.

 

Looking good, i like watching threads like this. I just repainted my frame again last week and used 2 component marine grade paint. Hopefully it keeps the rust at bay.

 

Subscribed! Love projects like this, doing the same to mine when the weather becomes a little predictable around here.

 

Day 5... Differential and exhaust...

Time to drain the differential


Differential looks good

All sealed up

Filled to the top

Exhaust in place (tail pipe goes on after bed)

Ford... Found On Recycling Day