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General => Build Threads => Topic started by: Rocketman on July 02, 2020, 09:51:05 PM

Title: 1994 XR2 resurrection
Post by: Rocketman on July 02, 2020, 09:51:05 PM
So as you may have seen in my other thread I traded an XR2 drivetrain for this 94 XR2.
It was bought as a donor for a Festiva, and slated to be chopped once the engine was pulled.
I put off going to get it as long as I could, I bought a 1993 Chevy truck in October to use for trips like this but it has taken me 8 months and countless man-hours to fix it up to pass PA state inspection.
Even still it was a bit sketchy and have found more things to fix on the truck, I had driven it maybe 300 miles before embarking on a 1,200 mile 3-state round trip to deliver the drivetrain and retrieve this Capri. Despite vomiting alarming quantities of gear oil from the differentials, the truck performed nominally and success was had in retrieving this diamond in the rough.

Freshly loaded:

(https://i.imgur.com/1kiUfFt.jpg?2)

(https://i.imgur.com/VlU53I1.jpg?1)

(https://i.imgur.com/pWJZS3D.jpg?1)

(https://i.imgur.com/K5rmOS0.jpg?1)

(https://i.imgur.com/QGjuA33.jpg?2)




Title: Re: 1994 XR2 resurrection
Post by: jdp on July 02, 2020, 10:00:57 PM
Thanks for a valiant effort to save a 94 from the scavengers! My 99 Silverado has 251,000 on it and keeps running strong. We drove it back to Pa last fall to help my son move. After all those miles, I finally had to put new brake pads on the rear. The fronts are still original. Old trucks rule!
Title: Re: 1994 XR2 resurrection
Post by: Rocketman on July 02, 2020, 10:06:01 PM
So, the issues thus far:

Vehicle doesn't run.
It is a Michigan car.
Fuel tank is thoroughly rotted out, fuel pump & sender assembly are shot.
There are no brakes, it appears several of the brake hardlines have corroded through.
There is some rust on the framerails, more on the passenger side, that will need to be inspected & repaired properly
The rear suspension is a little crusty, it looks like it can be saved though
The body has a whiskey dent in the front fender, and dings & scratches from sitting for 20 years
The top needs to be replaced

The good:

Only 83k miles
The interior is in amazing shape
No rust on the actual floor pan

In the car there was a receipt for an oil change dated May of 2002 with the mileage, it appears only 62 miles have been added since that date. Thus I am assuming it has been sitting since '02


I have not put a battery in it yet to check the electricals or to crank it, that is coming soon. I have ordered a fuel tank and will find a pump assembly from my parts hoard. I also need to order a roll of brake line and fittings and decide the best way to tackle replacing all the brake lines. If I pull the engine I'll have better access to the lines on the firewall, and can more easily replace timing belt/water pump/seals while the engine is out. But I have to hear it run first
Title: Re: 1994 XR2 resurrection
Post by: Rocketman on July 02, 2020, 10:10:52 PM
Thanks for a valiant effort to save a 94 from the scavengers! My 99 Silverado has 251,000 on it and keeps running strong. We drove it back to Pa last fall to help my son move. After all those miles, I finally had to put new brake pads on the rear. The fronts are still original. Old trucks rule!

Wow! This beast sits at 218k miles after the trip. It's easy to work on, but there was a lot of work to do. The looks were deceiving when I purchased it, the more I dug the more I found wrong. I performed significant rust repair & mitigation and repaired many mechanical issues. It turned into a heck of a project, which I was hoping was not the case when I got it, haha.

I wrote down all the repairs I've done one night, and filled an entire notebook page.  :(
Title: Re: 1994 XR2 resurrection
Post by: greywolf27030 on July 03, 2020, 07:25:37 AM
It's great that you elected to save this rare car. Good luck with it.

Jack Byrd
Title: Re: 1994 XR2 resurrection
Post by: Rocketman on July 05, 2020, 07:28:34 PM
Got the old fuel tank out without too much fuss. Never seen something rotted like this before.

(https://i.imgur.com/rCWhcLp.jpg?1)

(https://i.imgur.com/YFZEeEt.jpg?1)

It seems to have rotted from the inside out, crazy. The bottom outside of the tank is in great shape. The filler is quite bad, too.

New tank should be here tomorrow. I'll see if I can get it running and then work forward from there.
Title: Re: 1994 XR2 resurrection
Post by: greywolf27030 on July 06, 2020, 08:44:11 AM
wow
Title: Re: 1994 XR2 resurrection
Post by: Rocketman on July 08, 2020, 06:48:13 PM
New fuel tank arrived:

(https://i.imgur.com/ewBvYgL.jpg?1)

It's a Spectra MZ2B for the 86-89 323 or 88/89 Mercury Tracer. Pictures showed a raw metal tank but this one is painted silver.
Fit as it should, the only thing different was missing a little tab to hold a check valve or something for the vapor vent line. And there's some foam bits installed on the OEM tank for sound purposes I guess, this does not have them. No drain plug either. Snagged the last one on Amazon for a cool $78 with free shipping.

I got the tank in and tested the fuel system. Found the rollover switch was unbolted and laying in the trunk from someone else's troubleshooting. Easy fix.
Cranked the engine a bit before giving it fuel to get the oil moving, and then she fired up no problems. Had a decent lifter tick until it warmed up but it sounds real good now.

Talked to the guy I got it from, it sounds like it was last running maybe 4-5 years ago, but based on the shape of the fuel tank I kinda doubt it - who knows. The battery that was in it is a Ford Motorcraft battery, maybe from 96? The date code portion is torn off. Either way it's running now!

Took it for a spin around the parking lot, clutch feels good. But it has no brakes so a short spin was all I did. The shifter is stiff as can be, I suspect the linkage at the shifter is rusted, needs TLC.
My order of copper-nickel brake line, fittings, and a new flaring tool came in today so I'll be tinkering with making new brake lines for it. Not looking forward to all that.
Contemplating doing the Big Brake Upgrade on the fronts, it likely needs new rotors & if I'm going in there I might as well do it with future service in mind. I wish there was an easier Master Cylinder upgrade

Title: Re: 1994 XR2 resurrection
Post by: greywolf27030 on July 09, 2020, 09:53:34 AM
Nice
Title: Re: 1994 XR2 resurrection
Post by: Rocketman on July 15, 2020, 11:04:05 PM
Started on the brake lines.

There's a lot of small differences in the 94, it's interesting to see the little bits that changed. There's some sort of brake pressure switch on the firewall that is not present on the 91 I have. But the 91 has a cut out in the firewall insulation for the block. The plug for it runs into the engine harness.

Anyway, had to make a tight radius bending tool for this line, took two attempts, first time I cut it a bit too short. Oh well. Needed the practice anyway
This was the only line that I could visually see was completely shot, so I put some fluid in and pumped the pedal, and could hear it shooting out under the car. Apparently there's another busted spot in the rear line(s) where it comes out from under the engine subframe, at the base of the firewall. Looks like a joy to get to that area to replace those lines, even if I were to remove the engine. Any tips on that one??

(https://i.imgur.com/kIKJ21b.jpg?1)
Title: Re: 1994 XR2 resurrection
Post by: MagnumPI on July 16, 2020, 08:11:27 AM
I recently had to replace the rear brake lines, but luckily I had my engine out to replace some gaskets and the clutch.
It's a bit fiddly in that area, especially re-attaching the bracket which is hidden behind the steering rack, but all in all it went smoother than I anticipated.
A second pair of hands and eyes definitely helps and of course pre-bending the lines.
With the engine still in the car I imagine it being an unpleasant job.
Title: Re: 1994 XR2 resurrection
Post by: greywolf27030 on July 16, 2020, 10:32:34 AM
Very professional.
Title: Re: 1994 XR2 resurrection
Post by: Rocketman on July 20, 2020, 07:15:40 PM
More brake lines.
Decided to add a union just past the firewall to make the lines a bit easier to manage.
Driverside hardline was seized into the rubber brake hose. Had to cut the hardline to mount it in the vice to deal with it.
Checked the brake bleeder on the driverside caliper, snapped right off even with liberal use of heat and penetrating fluid. Will toss it on the milling machine and see if I can salvage it.
On the other hand, pulling the wheel off revealed factory fresh gold zinc plating on the hub & wheel studs.

MC to driverside wheel
(https://i.imgur.com/a2qqV5k.jpg?1)

Rear line 1
(https://i.imgur.com/rnCmuz3.jpg?1)
Title: Re: 1994 XR2 resurrection
Post by: redsteve on July 22, 2020, 09:52:08 AM
Ohhh...my what a lot of work.

Very fine work too.

I'm enjoying following this.

Steve
Title: Re: 1994 XR2 resurrection
Post by: belleaudb on July 23, 2020, 09:49:06 AM
A great Thumbs UP! 

Seeing the pictures of the fuel tank reminded me of my tank replacement. My tank was perfect except the vent line rusted away. I guess the rust is due to the factory galvanizing and coating being too thin in places.

CHOOKAS!!!
Title: Re: 1994 XR2 resurrection
Post by: Rocketman on July 23, 2020, 03:00:41 PM
Yes, a lot of work. A lot more work ahead of me too. Little bit at a time.

The stock tanks seemed to have a few weak spots, welding or brazing I'm not sure. Salt in a confined space like that probably doesn't do it any favours.


Here's the front passenger side brake line. This one was a doozy, heck of a time fitting it with the engine in place, but the copper nickel line is sooooo forgiving.

(https://i.imgur.com/C2KPf9P.jpg?1)

And all new bits coming from the master cylinder.

(https://i.imgur.com/uDyHuUz.jpg?1)

I've got to order another roll of line, but I should have enough to do the two lines on the rear axle.
I have decided to try to use the stock lines from the firewall to the rear axle, for the time being, if they will hold. See what happens. I have a friend with a shop with lifts, if I could manage to borrow one for an evening once I get the car more streetworthy it would be much easier to replace those two main lines. They don't look terrible, so we'll see I guess
Title: Re: 1994 XR2 resurrection
Post by: jdp on July 26, 2020, 10:18:08 AM
Nice work Rocketman.  I appreciate the pictures and your expertise.   

John
Title: Re: 1994 XR2 resurrection
Post by: Rocketman on August 03, 2020, 04:04:59 AM
Another week of tinkering.

Managed to get the unions done to the old lines:

(https://i.imgur.com/I941W2n.jpg?1)

These sucked to do. Hah. I wanted to stagger them and get them nicer looking but it's just so tight there, and working upside down isn't my favorite thing.

Front driver side caliper bleeder screw snapped. It was super rusted into place.
I had good luck another time using the milling machine to mill out the old bleeder without killing the caliper threads. I got it to work again but it was much easier last time. Chased the threads with a tap to freshen them up. Seized pretty bad, other 3 were totally fine.  ???

(https://i.imgur.com/ETG0cup.jpg?1)

(https://i.imgur.com/cnvrRPf.jpg?1)

The bleeders are M8x1.0 which apparently none of my local stores carry. And apparently a relatively uncommon size that they're kinda hard to find online. Speed-bleeders, yes. Found the standard ones in a big assortment kit on Amazon but not individually. So I grabbed one from my parts car for the time being

I went to replace the lines on the rear axle, and every flare nut is seized. I tried a lot of PB blaster and some moderate heat and no luck.
With the system sealed and in the interest of feeling like I made progress, I bled all 4 corners with the rear lines as-is and everything seemed to hold, pedal is firm.
I'll test drive it this week around the parking lot. So I may have to do all the lines firewall back at once, depending on how destruct-ey I have to get getting the old stuff apart.

So if anyone's got a decent rear brake junction piece for sale let me know
Title: Re: 1994 XR2 resurrection
Post by: greywolf27030 on August 03, 2020, 09:19:37 AM
You're the man. Have you ever tried a 50/50 mixture of acetone and antifreeze?
Title: Re: 1994 XR2 resurrection
Post by: jdp on August 03, 2020, 01:46:11 PM
I guess I should scavenge the bleeders out of my old calipers that I have laying around.
Title: Re: 1994 XR2 resurrection
Post by: redsteve on August 04, 2020, 04:45:50 PM
I second acetone and antifreeze as an option.

Another one: I gave up PB Blaster for Kroil as my go-to, a changed I made years ago and have stuck with.

Cool project and following...

Steve
Title: Re: 1994 XR2 resurrection
Post by: greywolf27030 on August 05, 2020, 09:44:26 AM
I second acetone and antifreeze as an option.

Another one: I gave up PB Blaster for Kroil as my go-to, a changed I made years ago and have stuck with.

Cool project and following...

Steve

I agree with the Kroil, it's just hard to find.
Title: Re: 1994 XR2 resurrection
Post by: redsteve on August 05, 2020, 08:17:00 PM

One of the local farm/ranch stores always has Kroil in stock, and bigger spray cans too. Still, if I need one can I buy two. Sometimes, they have one gallon cans in stock. It' expensive...but worth it (there's a lot of things like that...).

Steve
Title: Re: 1994 XR2 resurrection
Post by: Rocketman on October 25, 2020, 10:42:04 AM
So a non-update update, hah.

I still have not replaced the rear lines on the car, but they are holding for now. It moves in/out of my shop and thats where I needed to get it for now.
The past few months have been incredibly busy for me so no more work has been done on the 94.

I started a 2nd job playing mechanic at a local garage, so there is hope that I can get it in on a lift one weekend and very easily do the rear lines without breaking my back. I'd like to do this before snow starts to fly, and then I can figure out what I'm going to do to store it for the winter.

OOOOr continue to fix it over the winter, I'm not sure. I'm at a point where I've validated that it can be a good car, I'm at that stage where I have to start throwing money at it for things like brakes/rotors, tires, soft top, etc.
Title: Re: 1994 XR2 resurrection
Post by: jdp on October 25, 2020, 02:56:09 PM
You must have been reading my mind....I was wondering about your progress on the resurrection project.  Slow progress is still progress.
Title: Re: 1994 XR2 resurrection
Post by: greywolf27030 on October 26, 2020, 10:55:20 AM
Great that you are sharing a rare one.
Title: Re: 1994 XR2 resurrection
Post by: Rocketman on July 09, 2021, 09:09:21 PM
Update: After dragging ass on it for the past year, I've finally transferred the title to my name. And moved one of my plates to it. I had an afternoon off that gave me the time to get to the local notary place. Just haven't been able to find the time to get that done so haven't been able to do much else to it.
Life's been absurdly busy this year, I'm hoping to get something done with it soon while there is still top-down weather left.

Maybe updates soon??
Title: Re: 1994 XR2 resurrection
Post by: EShepherd on July 10, 2021, 07:53:15 AM
Hah, glad our conversation got some motivation going for you as well. I yanked my FR hub off yesterday...and then my son woke up from his nap. But hey, progress is progress, right?

I've been fixing up an old power wheels I found in the trash for him. I should put a build thread up here for that lol. At least it'll end up driving sooner than the Capri  :'(
Title: Re: 1994 XR2 resurrection
Post by: WashiestSnake on July 10, 2021, 03:54:14 PM
Awesome thread, cool to see you posting your own stuff here Matt rather then helping us with tech stuff. That XR2 looks super clean, glad you were able to get it so cheap, its in the best hands it possibly can be!

@EShepard, I for one would love to see a writeup of restoring a powerwheels for your kid :D. I feel as a community sharing things besides just our Capris will help us grow closer together, aswell as keep this forum a little more active.