What did you do to/with your van today?

[WE7X]

AStrophysics,
Nice setup. How does the bed fit in with that configuration?

Rod
WE7X
Issaquah, WA

[Astrophysics]

Hi,
For sleeping platforms, I fold down bench seat and use a self inflating Therma Rest mattress.

I have decided to set up my 2003 Astro more for gear and off roading. May actually set up small tent outside for camping.

This week I am doing the final research to actually install a 2 speed np231C transfer case and hook up a cable actuated t case shifter linkage.

I like the np231 shift cable from JB-custom-fab in Salem Oregon.

AP

[tomas]

AP, how's the np231 shift cable? We might need it as well.

[Astrophysics]

Hi,

I received the np231C shift kit from JB custom fab.
Very nice kit.
1. Single lever buggy style shifter with 48" cable with knob, $168.
2. Flush mount adapter kit $48

I got my 2003 up on ramps,
Pull rear drive shaft yesterday.

Will take photos.

The lever will be installed about 10" above the carpet next to driver seat.

The hole in floor will be rectangular opening, 1 1/4" X 4" for the linkage .

More later

Exciting stuff,

AP

[Astrophysics]

Hi,
JB custom fab kit is for np231 since that t case is used in many jeeps too.
The t case shift mechanism on the 231 differs from the one one the 233 case and from the splines on the np236 t case.
Jon B at JB custom has kit for np231 t case, but not for 233 or 236.

The 231 has the shift pattern shown in attached diagram.
Also, the 48" long cable is recommended for Astro install rather than the 36" length.

AP.

When the lever is pulled back that is 2Hi,
Then 2 fingers to push the lever forward for 4 hi, then neutral, and finally all the way forward for 4lo.

[tomas]

Nice AP. Good future reference.

[Herbie]

Agreed. I'm glad to see *any* amount of aftermarket support that benefits the Astro/Safari community. Can't wait to see how it all works out.

[Astrophysics]

Hi Everyone,

Got as far as the rear drive shaft removal with a small 6 point box wrench to reach the 8 mm hex bolts on the clamps. Stuck now doing income tax.

To safely R/R remove and replace old and new t case, I got Hydraulic motorcycle lift Jack at Harbor freight.

Spring is calling, gotta get these taxes done so I can do wrenching on Astro.

AP

[Astrophysics]

Photo of plastic spare tire dust/gravel guard and extra chain to secure tire

AP

[Astrophysics]

Hi,

Removed the np136 t case today. Lowered it with Harbor Freight hydraulic motor cycle Jack. Nice. Finally.
Need to double nut and remove the 5 studs from 36 t case and install in the np231C.

Then before installing the manual shift 231, I will cut the 1 1/4" X 4 1/2" rectangular hole in floor and carpet next to driver seat. That is where the JB Custom Fab cable shifter will be installed. Lots of room under van with t case and drive shafts out of the way.

I need to figure a clever way to mount a micr switch to the shifter to detect the 4 LO position so all 4 gears will shift in my 2003 automatic transmission.

AP

Tools:
15 mm for nuts holding trains mount
18 mm socket for transmission mount bolts
2x3 lumber fit under trans pan and suooirt wth bottle Jack to lift trans up to reach lower nut of t case
15 mm nuts qty 5 on t case studs
Strap t case to transmission Jack before removing the 4 other nuts.

[Wiley]

Had a shop press in bushings for my upper and lower control arms....FOR FREE! Woot, When I go back for an alignment I will slip they guy a few extra bucks, he said he was happy to help, hell yeah.

[Herbie]

After too many years with big gaping holes in my Surco roof rack, I did a quick and dirty floor insert using Ikea Runnen outdoor flooring tiles.

[Astrophysics]

Very nice
Interlocking pieces.
Strong.
Water and UV resistant.'
Good job

[tomas]

After too many years with big gaping holes in my Surco roof rack, I did a quick and dirty floor insert using Ikea Runnen outdoor flooring tiles.

Man that looks great and fits perfectly.

[WE7X]

I am in the process of installing a factory roof rack, on my '89. It never had one so that is 16 new holes and RivNuts. I also was given some extra cross bars (thanks Nonhog) so I will try using four or five.
I bought stainless steel RivNuts and had to buy a few new M6 x 30mm bolts. I already had a decent quality installation tool from a previous life, but is still a had powered tool, which uses a 'T' handle that has a socket for a 1/4" ratchet drive. I sure needed the extra leverage to get those nuts set completely. It is a slow process with this tool, but it works and therefore I cannot justify a better one.
The factory bolts were button head Torx, but I could not find any with the correct head diameter, so I had to drill out the countersunk mounts just a tiny bit for the minimally larger heads of the new bolts.