Project Chronicle

The 1989 Isuzu Trooper RS - after two years of moving it here and there, leaving it with different shops and seeing no progress - is finally running. And incredibly, it didn't even need that much to get to the day I had this weekend, where I drove it around the lot of Jay's 4WD and it drove as if it was never parked for 15 years in a junkyard. 

Jay, my shadetree mechanic who is working on the Trooper as a side-hustle, did a fair amount of work. But it's still somewhat of a short list given how long this truck sat dormant. He dropped the tank and replaced it with a rust-free one; rebuilt the fuel tree and installed a new fuel filter and pressure regulator; replaced all belts, some hoses, and the water pump and tensioer; rebuilt the front axles and front and rear brakes (calipers, rotors, and the passenger front hub); wheel bearings; and that's about it. He did plenty of diagnostic and investigative work, too, but from a parts perspective, it wasn't that extensive.

And here's the crazy thing: it drives REALLY NICE. With no real suspension work, oversized tires, and zero fluid changes in the transmission or transfer case, it just hooks up and goes! The transmission feels very tight, and the Troopers with the 2.6L had a very stout Aisin transmission, so it's good to see its reputation is holding up. 

The lights work, the front and rear washers and wipers work, the horn works, the gauges work....it's really pretty shocking. And right now, we're down to a valve cover gasket, some timing work, and changing the transmission and transfer case fluids. I'm going to have Jay throw on the bumpers and lights, and install new Old Man Emu shocks and bushings all around. I'm just stunned but also feeling a strong sense of redemption that this rare '89 Trooper RS was a real-deal 55K mile truck that fell into the junkyard due to some pretty insane circumstances. And while it still needs bodywork, I am more committed than ever after driving this 1-of-800 short wheelbase Trooper RS this past weekend.

Years ago, powder coating was kind of a taboo subject. It was sort of like - what, you're not baller enough to get your wheels professionally repainted when they lose their luster? It seemed that way at the time, but after having my first powder coating experience has changed my mind.

I had a set of wheels that would seem pretty ordinary on the outside. American Racing Outlaws in 15x7 with a 6x139.7 bolt pattern. Strangely enough, these are not entirely easy wheels to find. The other factor in my trying to keep these wheels alive is that the offset is perfect. The stance has always been one of my favorite details about the truck, as they poke out just enough to fill out the fenders without being obnoxious. 

Since I didn't want to risk shelling out $600 for another set and have them be all wrong, I had the original rollers powdercoated by a local shop. I am really happy with the results as the wheels were heavily corroded and a professional wheel repair shop would have charged a crazy amount just to prep them for paint. The wheels were originally polished; that finish is impossible to re-create affordably once it's gone, so they now wear a color known as "Heavy Silver." Looking forward to getting some properly-sized General Grabbers once we're at the point of bolting on wheels and tires worth more than the truck. 

After years of moving the 1989 Isuzu Trooper RS from one shop or storage locker to another, it finally left its latest home away from home running under its own power. It's a big day. 

The RS has gotten a crash course in resuscitation, with Jay over at Jay's 4WD rebuilding the brakes and fuel system along with installing a fresh timing belt in the course of a month after work and on weekends. Jay earned every bit of that bonus I promised him, and while we're not done, it was incredibly gratifying to see the truck leave the shop under its own power this weekend.

The Trooper has successfully gone into reverse and second gear, so fingers crossed the transmission will find the other two cogs before too long. Jay likely wants his shop space back - after all, we agreed to get it running, not restore it all the way back - but I hope he's willing to tackle a few more projects before I bring it home to begin the bodywork phase. 

The seat module saga for the Mercedes was more daunting than expected. There were rumors that a module from a W126 or W124 would work, which would have been helpful given those are much easier to find. Not true, as comparing photos of those modules with mine absolutely showed numerous pins in different locations.

There was a module for a 190E on eBay, but it specified it was for a 1991-1993 model. This didn't make sense, until it did: the later cars had the position of the telescoping steering wheel tied into the memory function of the front seat, which again led to pin locations not lining up with my car, which was a very early model with memory controls. 

So, I turned to Facebook, and found a 190E owners group that was predominantly made up of users from Europe. A shop in the UK that parts out and restores Mercedes came to the rescue, even going so far as sending video showing the seat moving normally with the module hooked up. Hopefully, this brings this chapter to a close and we can bolt a seat in securely and take the 190E Cosworth for a drive. 

As mentioned the other day, the Trooper RS is finally under the knife after two years of moving it around to various storage locations. My mechanic, Jay Gaston who runs Jay's 4WD, is in the thick of it at the moment, taking apart the front axles and brakes to refresh the components within.

The passenger side is back together, but we found the driver's side hub was pretty rough. The bearing race was just falling out, so I found a used replacement at Woonsocket Auto Salvage. New wheel bearings ordered front and rear, and we'll also track down a set of replacement control arms with new bearings pressed in at some point. The cool thing about that last job is this guy - known as Jerry Lemond - still has NOS parts in his barn from his days as the head trainer for Isuzu corporate. He bought out the domestic parts supply when Isuzu stopped selling consumer vehicles in the states.

As part of this, he's offered to have me send him a set of replacement control arms from a southern junkyard and he'll press in fresh bushings before sending them onto me. This project is a bit of a fool's errand - I'll not likely sell it for what I'll have into it - but I really do love this truck and want to see it come back to life. 

One of the dumber stumbling blocks with the junkyard-find 190E 2.3-16 Cosworth had to do with the interior. The original Recaro seats were in bad shape, so I bought a replacement interior not too long after acquiring the car. The one downside is the Recaros came without bases, so they had to be swapped off of the original, battered seats. 

Since installing the replacement seat, it would do one of two things: it would shoot all the way forward or all the way backward. The 190E regardless of seat options were all powered, so the easy fix was to replace the power seat switch, which also controls the memory. We replaced it twice with no change in behavior. Now, the reason I say this is a dumb obstacle is that the car actually starts up and idles quite nicely, but you can't very much drive it without a seat. Incredibly, the lack of easy resolution with the seat is one of the bigger reasons why this project hasn't moved much lately. 

My shop finally had some downtime today and found the source of the issues: the control box that sits under the seat definitely got soaked, with all sorts of corrosion inside the box. This most likely happened while it was sitting in the junkyard with no rear windows, courtesy of the yard "help" that smashed them out to get the window regulators (those and the radiator were the only parts they sold off of the car while it was inventoried.) 

The bad news is, not many used parts still exist; the good news is, you can buy one new from Mercedes. So, we'll order one up in hopes this lets us install the front seat and actually take it out onto the road. 

As I mentioned a few weeks ago, I was having trouble getting the lone gun mechanic I hired for the Trooper RS revival to start on the project. I dangled the prospect of a bonus, but what seems to have gotten things moving is that I'm now paying rent for this thing. 

Bear in mind: I did not pay rent for the six months it's been stored at a commercial property in Portsmouth, RI. But here's what I realized: if Jay, my mechanic pal gets hit by a bus tomorrow, there's no connecting him to me as far as the property owner is concerned. So, I pressured Jay into connecting me to the owner to kick-start an agreement, which not only provided me some ass-coverage but also made it clear that I was committed to this project - and now had even more skin in the game.

Who knows. Maybe the two are unrelated and I'm just an idiot for paying rent when no one was asking. But the Trooper did move indoors this weekend, with the fuel system being cleaned and replacement parts swapped in (gas tank, fuel pump, etc.) Jay let me know all of the calipers are condemned, so I just ordered replacement calipers to go with the replacement calipers and pads I sent over last year. 

The timing belt still needs to be done, but I'm hopeful we're going to see some real progress over these next few weeks.