I've been chasing a biodiesel leak on my wife's Suburban for the past month when I've had time. I have to get her back on the road so I can take the Ranger off the road! (she has my Dodge Cummins and I'm driving the Ranger)

The Montero is sitting in the driveway without engine waiting for the transplant.

Pmontero

Dylan, make sure you get the drop resistor in the front of the passenger side of the engine bay. I believe it is necessary to step down the voltage to around 6.5V for the glow plugs. When I get there, I plan to put my Multimeter on the glow wires and get a reading both for start glow and warming glow.

My latest progress:

-Pulled the entire front wiring harness out of the Ranger and sent the corpse to the scrapyard.

- Changed timing belts and accessory belts on the diesel, along with a few oil seals to hopefully eliminate any leaks.

- Need for parts has started to hold me up a little (looking for a water pump pulley mainly), and I'm also trying to keep my truck operational for another week or two so I can move into a new apartment. Not really looking forward to the mess that wiring will surely be, but I'm excited to be this far after a year of planning and gathering parts. I'll be sure and keep updating as I progress.

Okay, made a bit more progress. Had a machinist friend make a new water pump pulley since I couldn't find one.



Again.....



Pulled the 2.6 gasser this morning, here's the engine bay ready for cleaning and re-wiring.



Haven't looked at it too in depth, but it appears that the motor mounts don;t quite correspond between the two.... I'll post more pics later to show what I mean.

Very impressed that you are following through. What did the pulley set you back?

$75 to machine the new pulley and weld up a crack in my alternator bracket.

That's a sweet deal. I hate that I couldn't come up with anything for you. Apparently, older Ford parts are becoming more and more scarce ( NOT vintage, just odd items from the early 90's back to the late 70's). Dunno why, tho. Glad to see you're getting along with this swap. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Pulley turned out nice! Keep us updated! <img src="/forums/images/graemlins/cheers.gif" alt="" />

Nice pulley! It looks like CNC work. Does your friend have a CNC machine in house? If so, see if he'll give you the electronic template he used to cut the pulley. That could come in handy for others who come after...

Pmontero

I took the flywheel above to a machine shop in Newnan, GA and he cleaned and resurfaced it while I waited. Here are the "after shots."



Ain't it purty?
<img src="/forums/images/graemlins/notooth.gif" alt="" />

I drained the fuel tank and will remove it hopefully this afternoon. It goes to the radiator shop to be boiled out with the radiator which will be rodded out also.

The motor should be in the Montero this month or in early October.

Pmontero

I posted last week about the various hangups I have been running into. Motor mounts, flywheel/clutch, etc.

Motor Mounts are not matching up like anticipated. Below is a pic of the motor side mount from the 2.6 (on left) and the motor side mount from the diesel (on rt).



The difference in design is not the problem - notice the vertical mounting holes spaced far apart on the 2.6 and the narrow spacing on the diesel. There's no way for the motor mounts to interchange, so I am trying to figure out what I need to use or fab up for those.

As far as clutch and flywheel go, the ranger I stole the engine from used a hydraulic actuated clutch, where my truck is cable actuated. The flywheel/pressure plate assembly is about a quarter inch taller on the Ranger setup versus what came off my truck. I would just use the 2.6 setup and call it good, but the flywheel to crank bolt pattern is ever so slightly off. Also it would require a new starter that would extend far enough to engage the starter ring on the flywheel, which is set further back on the 2.6. See pic - 2.6 on left, ranger setup on right.




The oil pump pickup/oil pan situation is also holding me up.... The original set up was in a 2wd truck and will obviously not clear the front diff. So I was planning to use the stock 2.6 oil pan, but now will have to track down a stock Mitsu oil pump pickup for a turbo diesel 4x4, or fab up my own. 2.6 pan and pickup sitting on rt ( front sump) and 2wd Ranger TD setup on the rt ( rear sump).



So, I am trying to track down OEM parts for most of these problems, and hopefully will be able to find what I need.