Q8y's 91 Grand Wagoneer LS Build (Photo Dump)

[Q8y_drifter]

This is gonna be a big photo dump of pics I have related to this build. I started briefly working on it in 2016 when I first bought it, but most of the work was done within the last 3 years.

Quick history
I bought this 91 Grand Wagoneer back in summer of 2016. It is a GCC-spec Kuwait export model, though besides the metric gauges and exterior woodgrain-delete, this is pretty much just a standard 91 GW. It's a fairly rare vehicle here, since they were officially exported and sold by Chrysler for the 1991 model only right after the end of the first Gulf War. It came with the typical 360/727/229 combo, cordovan interior (only interior color option) and painted in Dover Grey. The vehicle was in terrible mechanical shape. At the time of purchase it had a little over 110k miles on it, the 360 ran like crap, trans was leaking fluid all over, 4wd didn't work, AC didn't work and heat was deleted. Besides the faded paint and a few dings here and there, the body was 99% rust free and so was the frame. I bought this vehicle with the full intention of completely LS/GM swapping the driveline, so all the running gear was pulled out soon after I got it.

As it stands today this project is about 90% complete and I'm still working on the remaining 10% (Mostly interior and AC work).

Current build spec sheet is as follows:
- 2003 5.7L LS1 with Comp 212/218 cam, F-body front accessory drive, Gen 3 truck intake and exhaust manifolds, Alan Grove Sanden AC compressor bracket, 411 PCM and CPW engine harness
- Novak Adapt engine mounts and radiator with Spal 19" brushless radiator fan
- 2006 Chevy NV4500 manual transmission with stock J-truck pedal box
- 1994(?) Chevy NP241C transfer case with Tom Wood's SYE and JB Fab cable shifter
- Tom Wood's F/R double cardan driveshafts
- Dana 44 F/R with 3.91 gears, Detroit truetrac rear LSD, lunchbox front locker and Mile Marker locking hubs
- BJ's Offroad brake hydroboost system
- Chevy S10 Blazer fuel tank with 6AN feed/return using Holley FPR
- Skyjacker 4inch lift springs and shocks
- 33x12.5R15 AT tires on 15x10 steelies

[Q8y_drifter]

The timeline will be out of wack for some pics so apologies in advance. You'll also notice I made a LOT of changes as the build progressed, the final iteration is as listed in the first post.

[Q8y_drifter]

[Q8y_drifter]

[Q8y_drifter]

[Q8y_drifter]

[Yeller]

lots of cool details! welcome aboard. Where are you located?

[Q8y_drifter]

lots of cool details! welcome aboard. Where are you located?

Thanks. I'm in Kuwait.

[letank]

Welcome, what an adventure.

The tailgate wire loom can be an issue, especially at the tailgate hinge area, the wires have to slip through a small channel and follow a certain motion which does not do well with old hard insulation.

At least no rust!

As for your steering issues, even with the computerized report, I would do a visual, using a line of sight from the front tire to the rear tire, using a virtual line with one eye from the outside of your front tire mid height such as hub level observe the field that can be seen of the rear tire. Repeat on the other side and it should be the same when the steering is pointing straight ahead. You can wiggle the steering a bit to compensate for an even field on both sides.

[Q8y_drifter]

Welcome, what an adventure.

The tailgate wire loom can be an issue, especially at the tailgate hinge area, the wires have to slip through a small channel and follow a certain motion which does not do well with old hard insulation.

Thanks!

Yeah I double checked all the wires that pass through the slits at the tailgate hinge and they all seem ok and still pliable. As far as the tailgate wiring goes, the tailgate window motor and switches all worked just fine. The rear wiper motor however was toast, completely melted and broken inside, while the glass defrost didn't work for some reason (I think the wiring behind the dash might be the issue). I ended up deleting the rear wiper washer system as I couldn't be bothered with it and installed a reverse rear view camera right where the wiper motor was installed. Works perfect.

As for the rest, all I really did was clean up all the contact and ground points and installed a relay for the window motor from BJ's offroad. I also installed their key switch conversion just as a precautionary measure, even though the original worked ok.

[Stuka]

Lot of attention to detail! Great work.

[Q8y_drifter]

Lot of attention to detail! Great work.

Thank you!

[Q8y_drifter]

[Q8y_drifter]