Frustration is the enemy of all automotive projects. Adding a front axle and transfer case to the equation only makes things tougher when it comes to working on your vehicle or trying to get a project completed. We know how frustrating your projects can be because we live it every day-just like you do. Actually we live it in a more concentrated form than most because our job is to get 4x4 projects done, on time, within budget, and in such a way that they don't fall apart when we're out on the trail.
Realizing that most of us drive and work on 4x4s because it is fun (it better be, after all!), we wanted to focus here on some of the small tasks that end up being huge time-sinks on everybody's rig. We'll help you turn your driveway-or garage-queen into a rolling, running 4x4 and help you through those times it might seem impossible to finish your rig.
We've learned that the key to any successful project is to take your time and focus on individual tasks rather than taking on the whole project at once. Concentrate on getting each subassembly done-and not just "it'll do for now" done, but done done. Looking at your project any other way will only lead to stress and unhappiness and is sure to turn what should be fun into work.
Zip Tie With a Twist
Second only to duct tape in terms of functionality is the nylon zip tie. They're so versatile and quick to install that most of our rigs have dozens, if not hundreds, of these do-it-all babies. If there is a downside to zip ties, it is the sharp nub they can leave after you snip off the excess nylon tie. These nubs are sharp enough to draw blood and, when grouped together, are the automotive equivalent of a thorn bush. We're sure you've been bitten at some point by a patch of zip ties tucked up under your dash while trying to install a stereo or a new switch.
There are a few ways to solve the problem. The cheap and slow way is to trim the nub flush to the tab with a razor blade. The expensive way is to use a pair of special end-cutting pliers to trim the nub flush without leaving a sharp edge. The cheap and quick way is the cut-and-twist method. Rather than using the common diagonal cutter to trim off the zip tie end, use a pair of lineman pliers to cut the excess down so that 11/44 inch remains. Then grip the nub as shown, and twist it 180 degrees until it breaks off. When done correctly, this procedure leaves a smooth edge that won't bite you the next time you are working in the area.
A word of caution: This technique works best with real nylon zip ties. Cheap plastic ties are likely just to break apart when you twist the nub off.
Checking for Vacuum Leaks
Some of the most elusive, and hence most frustrating, engine problems are vacuum leaks. Anytime the engine won't idle right or a piece of emissions equipment won't function properly, a quick inspection of the vacuum system is in order. Start by looking for obvious offenders, such as torn hoses, broken connectors or T-fittings, and just plain old dried, cracked, or worn-out vacuum lines. Chances are a visual check will pick up the worst offenders.