Four Wheeler - February 2016

FIRST LOOK!
THE NEW 2017 FORD SUPER DUTY
101
THE WORLDS LEADING 4x4 AUTHORITY
CHEAP TIPS
AND TRICKS
4x4 HACKS
NO-TO-LOW-BUDGET
LS-POWERED
THREE-DOOR
SUBURBAN
PLUS:
OLD-SCHOOL VIBE
WITH MODERN
TOUCHES
TOP TEN THINGS

YOURE DOING WRONG
RAMIMAL
AEV-UPGRADED
RAM TRUCK PACKAGE
FEBRUARY 2016
GELL-OUT
DIESEL COLD START CURES
SEE US AT FOURWHEELER.COM
LEARN MORE
ABOUT THIS BUILD
5 0 .1117 5 4 , -12 2 . 9 16 8 3 1
GRABBER ARCTIC LT
GRABBER AT 2
GRABBER HTS 60
Snow, Ice & Wet

Condition Traction
Aggressive
All-Terrain
Long Wear, Comfort

& Performance
#ANYWHEREISPOSSIBLE // LIKE US ON FACEBOOK.COM/GENERALTIRE
W W W.GENER ALTIRE.COM
CONTENTS
FEBRUARY 2016, VOL.53, NO.2
COVER SECTION
101 LOW-BUDGET TIPS & TRICKS

24 101 CHEAP TIPS & PROBLEM
SOLVERS
Get more bang for your garage-tech buck
FEATURES & EVENTS

16 2017 FORD SUPER DUTY
The new class of working class
38 THREE-DOOR THUNDER
Modern power with Classic Style
52 BACKWARD GLANCES
The 1947 Dodge WDX Power Wagon
that does everything
60 FLATBED E-350
Not your average shop truck
48
64
44
60
VEHICLE TESTS
48 AEV RAM TEST DRIVE
We found the inner off-road animal
inside the AEV Ram
TECH & HOW-TO

44 10 THINGS YOURE DOING
WRONG
16
24
DEPARTMENTS
ON THE
COVER:
7 FIRING ORDER / 8 INBOX /

10 RPM / 14 PARTS RACK /
68 TECHLINE / 71 CALENDAR /
74 TRAILS END
Got a
vintage
itch? Harry
Wagner has
just the
three-door
Burban to
scratch it.
Correcting common 4x4 errors
56 CUMMINS COLD SHOULDER

Five ways to combat Cummins cold-start
problems
64 BRONCO II BIO
A Ford SUV Spotters Guide
WWW.FOURWHEELER.COM
Brake Upgrade Kits

WWW.FOURWHEELER.COM
SIX FABULOUS CHOICES

to suit every driving style and budget.
All EBC rotors are now black GEOMET
corrosion resistant coated...
EDITORIAL
Network Content Director Rick Pw
Editor Christian Hazel
christian.hazel@fourwheeler.com, fourwheeler.com,
facebook.com/christianhazel3, Twitter @ChristianHazel1,
Instagram @hbombindustries
Managing Editor Lee Lovell

Senior Editor Ken Brubaker
These rotors WILL NOT RUST
ART DIRECTION & DESIGN

Art Director Greg P. Smith
MANUFACTURING &
PRODUCTION OPERATIONS
VP, Manufacturing & Ad Operations Greg Parnell
Senior Director, Ad Operations Pauline Atwood
Archivist Thomas Voehringer
READER SERVICES
Four Wheeler, P. O. Box 420235, Palm Coast, FL321420235, 800/777-0555, 386/447-6385 (intl), or e-mail
fourwheelr@emailcustomerservice.com. Please include
name, address, and phone number on any inquiries.
Occasionally, our subscriber list is made available to reputable firms offering goods and services we believe would
be of interest to our readers. If you prefer to be excluded,
please send your current address label and note requesting to be excluded from these promotions to TEN: The
Enthusiast Network, LLC, 831 S. Douglas St., El Segundo,
CA 90245, Attn: Privacy Coordinator.
NRS - NUCAP Retention System

creates a mechanical bond,
locking the friction to the
backing plate.
Vehicle Type
Prices From
Stage 1 Kit
Ultimax Daily driver pads & Geomet black OEM style rotors
Any Vehicle
$99
Stage 2 Kit
Greenstuff sport pads & USR slotted black Geomet Rotors
Car
$145
Stage 3 Kit
Greenstuff Trucksport pads & GD sport drilled black Geomet rotors
Truck/SUV
$175
Stage 4 Kit
Redstuff premium fast street pads & USR slotted black Geomet rotors
Car
$195
Stage 5 Kit
Yellowstuff highest friction pads & GD sport drilled black Geomet rotors
Any Vehicle
$245
Kit includes 100% British made ECO friendly quality high efciency EBC brake pads fully tested and
approved to meet or exceed all known standards plus premium Geomet corrosion resistant G3000 iron
rotors of your pattern choice. Geomet is the NUMBER ONE brake rotor anti corrosion surface coating used
by OEM builders (they use silver, we prefer black Geomet). Coating withstands severe salt spray tests for
corrosion resistance.
Ask at Pep Boys

or your local retailer or
shop online at ....
www.ebcbrakes.com
Canada Post: Return undeliverable Canadian addresses

to IMEX Global Solutions, P.O. Box 25542, London, ON
N6C 6B2.
Back Issues: To order back issues, visit https://www.
circsource.com/store/storeBackIssues.html.
Reprints: Contact Wrights Media at 877/652-5295
(281/419-5725 outside the U.S. and Canada) to purchase quality custom reprints or e-prints of articles appearing in this publication.
Submissions: Any submissions or contributions from
readers shall be subject to and governed by TEN:
The Enthusiast Networks User Content Submission
Terms and Conditions, which are posted at
http://www.enthusiastnetwork.com/submissions.
ADVERTISING INFORMATION
Please call the Four Wheeler advertising department at
310/531-9183. Related publications: Automobile, Car
Craft, Chevy High Performance, Circle Track, Classic
Trucks, Diesel Power, Dirt Sports & Off-Road, 8-Lug
HD Truck, Engine Masters, European Car, 4-Wheel
& Off-Road, Hot Rod, Hot Rod Deluxe, JP, Lowrider,
Mopar Muscle, Motor Trend, Muscle Car Review,
Muscle Mustangs & Fast Fords, Mustang Monthly,
Recoil, Street Rodder, Super Chevy, Super Street,
Truck Trend, Truckin, and Vette.
ADVERTISING
General Manager Steve VonSeggern
svonseggern@enthusiastnetwork.com
Associate General Manager Kurt Miller

Advertising Coordinator Gail Burns
Administrative Assistant Glenda Mack
Los Angeles Sales Office
831 S. Douglas Street
El Segundo, CA 90245
310/531-9900
Irvine Sales Office
1821 E. Dyer Road, Ste. #150
Santa Ana, CA 92705
949/705-3100
New York Sales Office
261 Madison Avenue
New York, NY 10016
212/915-4000
Detroit Sales Office
4327 Delemere Court
Royal Oak, MI 48073
248/594-5999
Midwest Sales Office
Jen Wittman
310/531-9896
Southeast Sales Office
Brit White
813/675-3479
To advertise on this magazines website,
or any of TEN: The Enthusiast Networks other
enthusiast sites, please contact us at
AM-advertising@enthusiastnetwork.com.
TEN: THE ENTHUSIAST NETWORK, LLC
Chairman Peter Englehart
Chief Executive Officer Scott P. Dickey
EVP, Chief Financial Officer Bill Sutman
President, Automotive Scott Bailey
EVP, Chief Creative Officer Alan Alpanian
EVP, Sports & Entertainment Norb Garrett
EVP, Chief Content Officer Angus MacKenzie
EVP, Operations Kevin Mullan
EVP, Sales & Marketing Eric Schwab
SVP, Digital Operations Dan Bednar
SVP, Sales Operations Matt Boice
SVP, Financial Planning Mike Cummings
SVP, Automotive Digital Geoff DeFrance
VP, Editorial Operations Amy Diamond
SVP, Content Strategy, Automotive David Freiburger
SVP, Digital, Sports & Entertainment Greg Morrow
VP, Digital Monetization Elisabeth Murray
SVP, Marketing Ryan Payne
EVP, Mind Over Eye Bill Wadsworth
CONSUMER MARKETING,
ENTHUSIAST MEDIA SUBSCRIPTION
COMPANY, INC.
SVP, Circulation Tom Slater
VP, Retention &
Operations Fulfillment Donald T. Robinson III
Copyright 2015 by TEN: The Enthusiast Network
Magazines, LLC. All rights reserved
PRINTED IN THE USA
WINTER
CAN BE FUN WITH THE RIGHT
VEHICLE PROTECTION
Check out our full line of Automotive Accessories at WeatherTech.com
Laser Measured, Custom-Fit
FloorLiner
Accessories Available for

Order Now: 800-441-6287
BumpStep
Cargo/Trunk Liner
Hitch Mounted Bumper Protection
Acura Audi BMW Buick Cadillac Chevrolet Chrysler Dodge Ferrari Ford GMC Honda Hummer Hyundai Inniti
Isuzu Jeep Kia Land Rover Lexus Lincoln Maserati Mazda Mercedes-Benz Mercury Mini Mitsubishi Nissan
Oldsmobile Plymouth Pontiac Porsche Saab Saturn Scion Subaru Suzuki Toyota Volkswagen Volvo and more!
American Customers
WeatherTech.com
Canadian Customers
WeatherTech.ca
European Customers
WeatherTechEurope.com
2015 by MacNeil IP LLC
FIRING ORDER
Inspector
Gadget
uitting time! I swiveled my chair

and squinted through the window
of my office on the 11th floor. I
could just make out a hint of the
I-405 freeway and a stagnant
line of automobiles not going anywhere
fast. Resigning myself to yet another 4-hour
commute home, I loaded my backpack and
headed for the elevator. In my pocket was
something brand new.
It was February 2007, and I was one of
the few early individuals to have an iPhone.
At the time I was moonlighting as a partner
in a software technology company, and
although I wasnt a gadgety guy, one of the
other partners definitely was. The first day
they became available, he moved heaven
and earth to get us all iPhones.
I stepped inside the crowded elevator and
instinctively swiped my phone alive to check
the time. No sooner had I noted it was 5:03

p.m., some spit-polished lawyer-looking dude
in a sport coat exclaimed, Hey, an iPhone!
He said it with such glee and fervor, just like
Steve Martin in The Jerk: The new phone
books are here! And before either one of
us realized it, he had snatched it right out of
my hand and was pawing and swiping and
navigating through my device. Now, Im not
what youd call a physically imposing dude,
but I have been toldmore than once, if
Im honestI sometimes give a look thats
downright scary in its intensity and surmised
promise. Its an involuntary thing, and if I had
to guess, its trigger mechanism is extreme
dumbassery. Sport Coat must have wound
up on the receiving end of it because as
he slowly realized his faux pas and meekly
handed my phone back, he looked like he
was about to wet his pants.
I laughed about it with friends afterward,
but at the time, I was blown away how a
fourwheeler.com
simple gadget caused this professional to

completely and (probably) uncharacteristically lose his composure. Its something
thats stuck with me to this day. Maybe its
because I see the same thing in so many
newer off-roaders.
The next time youre on the trail, take note
yourself of how up-trinketed some of these
vehicles have become. Little widgety brackets and pods and mounts strung all along the
interior, rising up from the dash and dangling
down from the rollcage. They hold phones
and navs and tuners and sat radios and
cameras and all sort of other crazy things
that wink and blink and make toast and iron
your shirt. Are these guys really in need of all
that computing power or is it just technology
for technologys sake? Is it so they can outstrut their buddies at Starbucks and post on
4x4compensationpackage.com about their
shiny gadget that
nobody else has?
I dunno.
To paraphrase
the movie Airplane, complexity
can be pretty complex some times.
Personally, Im not
a fan of electronics of any kind
when it comes to
off-roading. That
goes for GPS and
CBs and even music. If you need em, turn
em on and find where you are or call for
help but then turn em back off and enjoy
the outdoors. I dont get folks who wheel all
day with their heads buried in a navigation
screen or incessantly jaw into their CB. I
prefer my builds analog and almost devoid
of superfluity. Heck, most of my rigs still
have incandescent headlights and carburetors. But despite how opinionated this editorial may seem, I honestly want to know what
trinket would make you go all Sport Coat if
you saw it in somebodys 4x4 and why? And
if you make an argument strong enough, Ill
print your letter in a future issue and send
you some Four Wheeler license plates and
stickers for your 4x4if you can find room
for them in amongst all your electronic
trinkets!
-CHRISTIAN HAZEL
CHRISTIAN.HAZEL@FOURWHEELER.COM
PHOTOGRAPHY: CHRISTIAN HAZEL
D
E
R
E
COV
T YOU
O
G
E
WE V
more info @
bushwacker.com
INBOX
AD PACKAGE
FIRST DRIVE: RAM REBEL OFF-RO
THE WORLDS LEADING
4x4 AUTHORITY
WICKED OFF-ROAD RANGER

WITH BUILT 5.0L V-8
HOW TO GET
POWER & TORQUE

FLASHBACK:
OVERLANDING!
74 INTERNATIONAL
CAMPER SPECIAL
VEHICLES, GEAR,
EQUIPMENT
OCTOBER 2015 $5.99
CAN DO IN A DAY
11 ENGINE UPGRADES YOUIONS
FUEL-INJECTION CONVERS
SWAP
ADD 68 HP! 5.7L VORTEC CAM
CRATE ENGINE OPTIONS
E
CRATE UPGRADION
JK AXLES INSTALLAT
SEE US AT FOURWHEELER.COM
EDITORS NOTE:
Every now and then
I ask for reader input
in the Firing Order
editorial column.
Heres a few blastfrom-the-past letters
from when I asked
readers to share their
shop photos by sending images to me
at christian.hazel@
fourwheeler.com.
SPIFFY BIFFY
I had recently purchased a standby electric
generator. I was looking forward to the return
of my contractor, the completion of insulation, and covering the walls after the electric
incinerating toilet was installed. Now, this is a
good time to tell you the value of insulation in
the Northeast. With only about 80 percent of
the walls insulated and two layers in the loft, I
used one-fifth the electric power than I did in
February of the previous year without insulation, despite the subfreezing temperatures.
I think this bodes well for next winter when I
plan to be spending more time working in the
garage, when Im working out there I usually
turn propane heater up to 60-65 degrees.
In the first photo you can see where the
old wall meets the new one. It was also at
this juncture that we built the toilet stall. The
last photo is of the completed stall and toilet.
One of these days,
when the weather
improves, Ill get
my sprayer out
and finish painting
everything. Oh, and
not wanting to waste
space in the stall,
I used a 1-inch-
BY CHRISTIAN HAZEL CHRISTIAN.HAZEL@FOURWHEELER.COM
SHORT AND SWEET

Here is my garage: It is 54 by 28 feet and
measures 1,512 square feet. The motorhome
you see is one that ran in your magazine a
while back. I added the motorhome part of
the garage myself. It is 28 by 14 feet.
CHUCK SPEYERER
VIA EMAIL
diameter oak dowel rod to mount three rolls

of paper between the studs on one side and
the toilet bowl liner dispenser on the other. On
the inside of the door are two signs I made.
The first draws attention to the fact that this
is an electric toilet and instructions must be
followed, and the second lists the three steps
to correctly use.
In another few days my flammable liquids
storage cabinet should arrive. I wasnt going
to purchase it this soon, but I got a deal that
included free shipping but had a time limit.
So its finally all coming together, and perhaps
later this summer Ill be able to swing the
larger air compressor, but probably before
that, Ill buy a big CO2 fire extinguisher for
each end of the building. The garage and
contents are too valuable to trust to fate alone.
Oh yeah, I havent chosen workshop cabinetry yet either; I may try to build that myself as I
know where I can buy premade maple butcher block countertops, as well as heavy sheet
steel. Like I tell my wife, its not a showcase
but when I do die, somebody will be getting a
darn nice garage/workshop.
FRANK CAPRISTO, JR.
VIA EMAIL
SCOUT SHOP
My wife and I have had about seven different houses over the years and my only
WHERE TO WRITE
ddress your correspondence to Four Wheeler, 831 S. Douglas St., El Segundo, CA 90245 or send
an email to christian.hazel@fourwheeler.com. All letters become the property of Four Wheeler,
and we reserve the right to edit them for length, accuracy, and clarity. The editorial department can also
be reached through the website at fourwheeler.com. Due to the volume of mail, electronic and otherwise,
we cannot respond to every reader, but we do read everything.
8 FEBRUARY 2016 FOUR WHEELER
requirement was that there had to be some

type of garage for my projects. Many years
later and after retiring, I finally built my ideal
shop. The 30x40-foot barn shown here is
that product. The raw lumber came from our
woods, sawed by a portable sawmill, and was
erected solely by me. The 10,000-pound
post lift is what allows me to follow my new
passion: building and wheeling IHC Scouts in
the Southeast mountains.
JOE SMITH
VIA EMAIL FW
fourwheeler.com
SHOP BY VEHICLE OR TALK TO AN EXPERT
All Terrain
T/A KO2
Blizzak DM-V2
Dueler A/T
Revo 2
Extreme Country
Dynapro AT-M
Road Venture
AT51
LTX A/T 2
Scorpion Winter
Grabber
Scorpion ATR
Wrangler
DuraTrac
Geolandar A/T-S
MO975
17 18 20
MO970
MO976
17 18 20
American Racing AR23

14 15 16
B.R. 937 Type 8P Steel

17
BRAKES
18 20 22
Granite Alloy GV8

17 18
Method Roost
17 18 20
Granite Alloy GA640

16 17 18 20
MAMBA M18
15 17 18 20
KMC XD XD823 Trap

18 20 22
WORX 806 Triton

17 18 20
SUSPENSION
TUNING
2015 Tire Rack
888-981-3957
MC XD XD822 Monster II ATX AX198 Chamber II

17 18 20
15 16 17 18
Ultra Xtreme X-Lok

16 17 18
LIGHTING
WIPERS
M-F 8am-8pm EST

SAT 9am-4pm EST
W. E.R. 504 Legacy

16 17 18 20
RPM
BY TORI TELLEM
EDITOR@FOURWHEELER.COM
AUTOMOTIVE NEWS
Thats Interesting
The Audi Q7 has a redesign
coming in 2016 and will be lighter
than the previous model.
Audi also has a new Land
Rover and Mercedes-Benz GL
competitor coming: the Q9. Except it is a couple years away.
As we went to press,
Volkswagen was facing accusations that it has tweaked software
in its diesel vehicles in order to
have them emit lower emissions
and squeak by in testing. VW was
said to be holding onto $7.3 billion
in order to fix the cars and meet
standards.
The U.S. Army and Marines
Corps have given Oshkosh $6.7
billion to build the replacement
for the Hummer. The Joint Light
Tactical Vehicle (they call it JLTV)
will probably have a GM Duramax
V-8, and there will be both two-
and four-seaters. Platforms will be

the utility, general purpose, and
close-combat weapons carrier.
Nissans hit a milestone:
3 million vehicles built at its Canton Vehicle Assembly Plant in
Mississippi. The Titan and Frontier
are two of the vehicles built there.
Speaking of the Frontier, the 16
model will range in pricing from
around $18,000-$32,000.
OnStar is adding AtYourService
to the RemoteLink app, which will
we will be getting the diesel Wrangler and the Wrangler pickup:

more capacity. And 2018, in case
you wanted a year in which to
plan your floor pacing.
provide retailer and merchant offers. Dunkin Donuts, for one.
Looks like the Jeep Wrangler
won the waritll keep being
made in Toledo, Ohio. The Cherokee will be uprooted to another
state but close by. And this is why
The most sought-after used

cars? Edmunds.com analyzed
things and learned that the
Dodge Magnum has millennials
going nuts, buying it more than
any other used vehicle. Other
flashbacks? Chrysler Pacifica and
Pontiac Aztek. The other Top 10
sellers from January to June 2015
included the Chevy Trailblazer and
Dodge Durango.
Fun things to ramble about at
the dinner table, courtesy of Ford:
78 percent of government workers
use the Super Duty; 81.7 percent
of workers in waste management
use one, too; and 61 percent of
sewer, water, and pipeline construction workers use an F-150.
Autotrader.com found that
between January and June 2015,
black was the most searched for
color.
Hondas built its 30 millionth
vehicle in North America.
Toyotas Huntsville, Alabama,
plant made its 4 millionth engine.
To break that down, its 1 million
four-bangers, 1.3 million V-6s,
and 1.7 million V-8s. Engine number 4,000,000 was on the fourcylinder end of things.
fourwheeler.com
Photography: Courtesy of the Manufacturers
Is It True?
Could it be true that the Jeep Grand

Cherokee Hellcat/Trackhawk is gonna
make numbers like this: 0-60 mph in 3.5
seconds?
Lexus, can we like this diesel chatter?
Land Rover, can we like this diesel

chatter about every vehicle getting a diesel
option?
Remember those guys who hacked the
moving Jeep to show its vulnerabilities? Did
they get hired by Uber to work on vehicle
security?
Bentleys SUV will be called Bentayga
and start at $229,100 when it arrives in
2016? And will it end up being a bargain
compared to the Rolls-Royce one due in
2018 for $400,000?
Automatic braking will become a
standard feature on all new vehicles from
brands such as GM, Ford, and Toyota?
Is our new fear supposed to be
kidnappers faking it as Uber drivers? And
is this a good reminder to those of you using ride-sharing apps to always compare
the license plate, name of the person, and
vehicle description provided by the service
before getting in?
Sounds like all Ram 1500 production
will soon be coming to the USA?
High quality monotube

construction in a full black
out package Stealth has the
edge when it comes to superior
ride quality for your vehicle at an
affordable price.
Welcome to the dark side.
Black Shock Body
Black NitroCarb Piston Rod
Excellent Ride Quality
fourwheeler.com
WWW.FABTECHMOTORSPORTS.COM
rpm
2016 Jeep Wrangler Black Bear and Two New Mopars

he Wranglers got a new edition: Black
Bear. Start with a Sport S and then add
rock rails and a bumper applique. The crown
de resistance is the ode to the Black Bear trail
in Telluride, Colorado: a hood decal and topographical trail decal.
On the Mopar side of things, theres the

Jeep Cherokee KrawLerthe capd K and L
stand for KL, which stands for the production
codeand the whole thing stands for extreme off-roading, with a unique suspension,
rock rails, skidplates, wider fenders, and a
military look. Meanwhile, the Rubicon Sunriser is all about the matte-orange paint and
Mopar accessories, such as a 4-inch suspension lift, LED lights between the A-pillar and
windscreen, two towhooks in front, and halfdoors. Under the hood is a 2.8L diesel.
Government
Your
At Work
An option to pay a $200 smog
abatement fee in place of passing
a smog test bit the dust in California legislature.
Michigan is pondering a
road-user fee: $50 per 10,000
miles driven in a one-year period.
Seems the National Highway
Traffic Safety Administration is too

understaffed to deal in a hyperfocused way with cybersecurity
issues related to vehicles, aka
hackers.
The U.S. Postal Service has
ordered more than 9,000 Ram
ProMaster 2500 cargo vans for
mail service.
Range Rover Sentinel
ts a first, as in the first armored Land Rover engineered by its

Special Vehicle Operations division. Range Rover claims the highest levels of protection an SUV can offer against a wide variety of
attacks. You know, the stuff like TNT, grenades, and high-velocity
armor-piercing incendiary bullets. Theres also an antitamper exhaust,
a 4-inch opening in the drivers window for document delivery, antismash protective glass, and a self-sealing fuel tank. And, yes, theres
an Emergency Escape System behind the rear seat. Options include
a fire-suppression system, external speaker system, and configurable
siren. And driver training is provided. For now, its available in Europe,
the UK, Africa, South America, and the Middle East.
fourwheeler.com
Whats
Happening
THE FIRST NAME I N

O F F - R OA D INNOVATION.
In The
Industry
Dick Cepek has a new website thats

also mobile-friendly: dickcepek.com.
Holley has bought MSD Group, which
includes MSD, Edge, Superchips, and Accel.
Check out partsmatter.com. The site is

holding a sweepstakesthanks to sponsors like Fel-Pro and Championin which
people can win weekly with their carnage
photos or videos of parts failing.
Youll know when Rugged Ridge is at
an event in 2016. The company has a new
custom 53-foot trailer plastered on the outside with its famous Mango Wrangler.
More time-wasters at work: Our sister
Motor Trend now has motortrendondemand.com, a subscription video-on-demand service with 1,000-plus hours of auto
programming. Check out racing, original
series, documentaries, and more.
Air Lift has expanded. Its headquarters
is in Michigan and will now have an extra
40,000 square feet of both warehouse and
manufacturing space.
PREMIUM ACCESSORIES FOR

JK WRANGLER AND RAM TRUCK
Bruiser Conversions Jeep JK Crew.

eBay. $178,000.
Four Wheeler App
his is how our app is described:

Each issue of Four Wheeler presents a wide range of informative articles
including adventure travel in the U.S.
and abroad, domestic trail rides and
event coverage, comprehensive newvehicle testing and evaluation, technical
articles designed for four-wheelers of
all abilities, as well as how-to installation
articles, equipment guides and comprehensive product testing. We kinda concur. Get it at the Apple app store. fw
fourwheeler.com
AEV CONVERSIONS.COM
FOUR WHEELER FEBRUARY 2016 13
PARTS RACK
BY HENRY MUELLER EDITOR@FOURWHEELER.COM
UNDER ARMOR
Theres nothing worse than taking your newly built JK into the rocks for the first
time and hearing that sickening crunch followed by leaking fluids. Now you can
add 316-inch-thick laser-cut skidplates to the underside of your 07-current JK
Wrangler thanks to Rubicon Express. The skidplates install with no cutting
or modifying required and feature a nice powdercoated finish to resist
corrosion. INFO: Rubicon Express, 800/776-0767, rubiconexpress.com
EZ ROCKER
REACH
For a vehicle with
such a large footprint
there really isnt much
space inside a JK Wrangler to mount many aftermarket accessories.
And even if you do find
space on the outside for
things like lights, compressors, or anything
else you may not want
running all of the time,
finding free spots for
rocker switches can be
frustrating. Daystars APillar Switch Panel (PN
KJ71056BK) is a neat
solution for at least one
of your Wranglers space issues, allowing you to install four
illuminated rocker switches right in easy reach on the driverside A-pillar. The kit comes with a pre-molded housing and
four illuminated rocker switches. INFO: Daystar, 800/5957659, daystarweb.com
ENERGY UPGRADE
Red or black. Thats about the only thing you have to think
about when it comes to firming up your Ford F-250 or F-350
Super Dutys suspension. Improve your handling and ride
quality, get rid of mysterious clunking, and add durability and
longevity with new polyurethane front and rear sway bar bushings, front and rear bumpstops, front spring isolators, front
track bar bushings, rear leaf-spring bushings, and cab body
mounts from Energy Suspension. Dont own a Super Duty?
Not to worry: The company almost certainly has products for
your application. INFO: Energy Suspension, 888/292-1250,
energysuspension.com
LARGE SMALL BLOCK
The 400ci small-block Chevy was only manufactured for a

few years, but it was offered in virtually all of GMs large land
barges. Naturally, that includes 4x4 pickups and SUVs. If your
small-block-powered anything needs a refresh in the engine
department, wed highly recommend BluePrint Engines new
400ci small-block crate engine. Offered in two versions (460 hp/470 lb-ft
or 508 hp/473 lb-ft) the engines are available in either base or fully dressed
(intake, carburetor, distributor) and feature high-quality components like 64cc
aluminum cylinder heads, hydraulic roller cam, hypereutectic or forged pistons,
and more. INFO: BluePrint Engines, 800/483-4263, blueprintengines.com FW
fourwheeler.com
WILDEST &
WETTEST
UA EVER!
Order your DVD now and get
in on the action as 22 4x4s
drive to survive a week of the
wettest, muddiest & toughest
trails in the Appalachains.
Follow as our ULTIMATE
ADVENTURE SUMMER CAMP
winds through Kentucky,
North Carolina, Ohio,
Tennessee, Alabama
& Georgia
COLLECTORS EDITION
EXCLUSIVE 90-MINUTE
DIRECTORS CUT
ORDER NOW!
OffroadPowerProducts.com
855-4OFFROAD Only $17.99
FIRST LOOK
The new class of working class

By Sean P. Holman
editor@fourwheeler.com Photography: Courtesy of Ford Motor Company
2017 FORD SUP

fourwheeler.com
IKE A CANNONBALL INTO A KIDDIE POOL, THE ORIGINAL
Ford Super Duty made such a splash 17 years ago,

that the truck market was forever changed. Breaking the heritage of sharing their cab with the F-150,
the Super Duty truly brought a vehicle so large and so
much more capable to market, that it was its own class of
truck. With 44 configurations and GVWRs all the way
up to 19,000 pounds in the F-550, the Super Duty had the
heavy-duty truck market covered. For its entire lifespan,
the Super Duty has been refined and improved to ensure
it remained relevant in hotly contested truck space. Its
remarkable to note that Ford claims a full 43 percent of
the registrations in the 8,500 to 14,000-poung GVWR
segment, while nearly 65 percent of all new chassis cabs
sold are Fords. Clearly the heavy-duty market is hugely
important to the success of Ford Motor Company.
Overview
PER DUTY
fourwheeler.com
For the 17 model year, the Super Duty is enjoying its

first complete redesign in nearly two decades, with what
Ford is calling the most significant product action in
17 years. The basic aluminum body structure is shared
with the handsome F-150, but the front clip, hood, fenders, lights, and beds are all unique to the Super Duty.
The new mil-spec aluminum body is stronger than
the old steel body and more dent resistant. In order to
handle higher loads, the Super Duty uses thicker gauges
of aluminum in key areas. For example, the Super Dutys
8-foot box has 14 percent more aluminum than the
F-150s comparable box by mass. A new floorpan pattern
with wider, deeper beads is also thicker, as are the box
inner bed panels and the D-pillar. The beds use stronger
crossmembers and a new one-piece sill reinforcement.
So how much would you guess the Super Dutys mass
benefitted from the switch to aluminum? It would stand
to reason that if the F-150 is in the 700-pound range, that
the Super Duty must be 800 or 900 pounds, right? Well,
not exactly. Ford pegs the number at somewhere around
350 pounds net. So what happened to that extreme diet?
The answer is simple: Ford reinvested the weight savings
right back into capability, while still light-weighting to an
impressive degree.
Because the switch to an aluminum body resulted in
such a massive weigh savings (Ford says more than 500
pounds from the old steel body to the new aluminum
one), the company focused on increasing already stellar capability. Ninety-five percent of the fully boxed
frame is made from high-strength steel, using rails that
are 112-inches taller, resulting in a frame stiffness that
is up to 24 times higher than the old frame. Other improvements include larger axles, heavier-duty driveline,
bigger brakes, and tougher transfer cases. Additionally,
all Super Duty trucks now come standard with weight
carrying hitches.
While the company wont be releasing hard numbers
until next year, the new truck is being referred to as the
most capable Super Duty ever. Ford tells us these trucks
will have the highest payloads and highest fifth-wheel/
gooseneck/conventional towing rating of any Super Duty
to date. As the year progresses, we are sure those claims
will expand to include best-in-class bragging rights.
Powertrain
You wont find any EcoBoost engines lurking under
the Super Dutys aluminum hood, as Ford has decided to
stick with the familiar for its powertrain offerings. Carrying over are the 6.2L gas V-8, 6.8L gas V-10 (chassis cab
only), and the potent 6.7L Power Stroke V-8. An all-new
FEATURE 2017 FORD SUPER DUTY

six-speed transmission, which Ford is calling
the TorqShift-G, will also debut behind the
6.2L gas V-8. The rest of the lineup will get a
version of todays six-speed 6R140 TorqShift
transmission.
Ford hasnt released many details about improvements or power outputs of these engines,
but we do know that the SOHC 6.2L V-8 will
benefit from larger intake valves and dual-equal
variable cam timing. It will also be E85 capable
and available with a CNG/propane prep kit (as
will the three-valve V-10 on chassis cabs).
The biggest unknown is just where the
popular 6.7L Power Stroke V-8 will end up in
regards to horsepower and torque. Ford tells
us we can expect improved performance
and fuel economy but nothing to indicate to
what extent. Weve heard over and over again
that Ford has its sights set on being the first
manufacturer to reach 1,000 lb-ft of torque.
We believe it to be highly likely that they will
reach that number, along with around 450 hp,
but it is all conjecture until Ford decides to
make an official announcement.
Link storage and cleat system. The shortbed

of the Super Duty also retains the front stake
pockets, something that is curiously lost on
the F-150 shortbox and a shortcoming for
those who use bedrail-mounted racks for work
or action sports.
Interior
Using the F-150s body has benefitted the
Super Duty with up to 6 additional inches of
cab length over the outgoing truck, resulting in a roomier cabin. The Super Duty also
shares the dash and totally flat rear floor with
its 12-ton brother but adds some unique storage solutions, such as a two-tier glove box and
dividable and locking rear underseat storage.
The higher-amperage upfitter switches have
been moved to the overhead console and
now include a total of six, two of which are
powered at all times. Other items shared with
the F-150 are an 8-inch productivity screen,
improved trailer brake controller location,

multi-contour seats with optional massaging
function, inflatable rear safety belts, and you
can now get up to two 400W/110V power
outlets.
Technology
Perhaps the biggest story about the Super
Duty is just how loaded with technology it is.
At the heart of these upgrades are up to seven high-resolution cameras. A forward facing
camera in the grille, side-view cameras in
the mirror bases, and a new camera in the
tailgate work together to provide the 360-Degree View with Split-View system introduced
in the F-150. A new CHMSL camera is
available over the bed to make hooking up a
gooseneck or fifth-wheel trailer easier, even
including a new zoom feature so you can see
the hitch. A remote-mount rear camera can
be placed on the back of your trailer to make
Exterior
One of the controversial new features of
the Super Duty is the vertical placement of
the model name in the functional fender vent.
Weve never seen the F-Series use this type of
treatment, and being on a black background, it
doesnt allow the color of the vehicle to come
through the logo as it does on the F-150. This
new design touch might be one that takes us a
while to get used to.
Features we do love are the F-150s LED
bed lighting system, the latest version of the
tailgate step, the availability of Fords Tough
Bed spray-in liner, and the F-150s new Box-
fourwheeler.com
29%
OFF
DRIVE IT.
RACE IT.
LIVE IT.
GET IT. NOW.
FOR
LOYA
LP
USE
RINT
PROM
GET
FOR
SUBS
O CO
CRIB
M O T DE:
O
OUN R
DISC
ERS
THE WORLDS PREMIER DESTINATION FOR AUTOMOTIVE VIDEO CONTENTMOTORSPORT,

ORIGINAL SERIES, MOVIES, DOCUMENTARIESAT YOUR FINGERTIPS.
SUBSCRIBE TODAY
MOTORTRENDONDEMAND.COM
FEATURE 2017 FORD SUPER DUTY
WEVE HEARD OVER AND OVER AGAIN

THAT FORD HAS ITS SIGHTS SET ON
BEING THE FIRST MANUFACTURER TO
REACH 1,000 LB-FT OF TORQUE.
reversing trailer maneuvers easier, giving you
visibility never before possible when towing.
In fact, Ford has included a new color-coded
trailer coaching system to alert the driver if
trailer angle becomes too tight or close to
jackknifing. Finally, a forward facing camera
at the top of the windshield provides lane
departure warnings and facilitates adaptive
cruise control, a feature that is now tied into
the exhaust brake for exceptional downhill
speed control.
In addition to the cameras, the Super Duty
is now equipped with blind spot monitoring,
and unlike the F-150, it remains functional
when a trailer is attached. Tire pressure monitoring will now have the ability to monitor
trailer tire pressure.
About the only thing the Super Duty
doesnt have is the F-150s Pro Trailer backup
assist. Unfortunately, the Super Duty chassis
isnt equipped with the same electric-assisted
EPAS steering setup as the F-150, so the
capability isnt baked into the platform as it
is on the 12-ton trucks. However, it will use a
new adaptive steering system that will be able
to adapt to different driving situations and

reduce the amount of steering input needed,
depending on speed and load.
The Super Duty will also benefit from the
all-new and much-improved Sync 3 communications and entertainment system, along
with support for Siri Eyes Free.
Initial Thoughts
With regular cab, SuperCab, and Crew
Cab layouts; two drive types; 612 and 8-foot
bed lengths (or a chassis cab); F-250, F-350,
F-450, and F-550 models; and XL, XLT, Lariat, King Ranch, and Platinum trim levels,
the dizzying array of choices available with
todays truck essentially carry over for 2017.
The virtually limitless combinations should
mean that there is a truck available for every
conceivable need.
On a side note, wed venture to guess that
the 350 pounds of weight savings will back
the curb weight off enough from the 14,000
GVWR for the F-450 pickup, that Ram will
have to drop the companys protest of the
F-450 being in a higher weight class, but we
are interested to seeing the response. No doubt

Ram is readying one.
Our only negative takeaways were the lack
of features we are beginning to see from the
competition. No options for air springs, in-bed
storage, or bed mounted power outlet seem
like potentially missed opportunities, but we
doubt the consumers will care much considering just how many class-exclusive features are
available. We also wonder if the F-250 will
see a detuned, higher-economy version of the
Power Stroke engine to better compete with
the upcoming Titan XD. We think consumers in the market for middleweight capability
would clamor for such a truck.
From what we know so far about the new
Super Duty, there is a lot to be excited about,
with much, much more news to come. Ford
assures us that we wont be disappointed by
the end results, which are a quieter, tougher,
smoother riding, more capable, and more powerful Super Duty. Will this truck be deserving
of the 13-inch Blue Oval on the grille and
poised to carry FoMoCo into the next chapter
of the heavy-duty pickup wars? FW
fourwheeler.com
TECH
CHEAP
TIPS
& PROBLEM
SOLVERS
101
Get more
bang for your
garage-tech buck
By John Cappa
editor@fourwheeler.com Photography: John Cappa
F THE SIGNIFICANT OTHER HAS TIGHTENED UP THE 4X4 PURSE STRINGS AND THE ONLY THING
collecting in your pockets is lint, then we have the cheap tips you need. We also threw
in some problem-solver components that have made our garage wrench, fabricator,
and off-roadcentric lives easier.
1. Mini-Station
2. Wheel Evaluation
Welding on the ground is uncomfortable and

not ideal for throwing down a good weld bead.
Build or buy yourself a thick steel welding table.
Weve been using this portable Miller (millerwelds.
com) F-Series ArcStation for several years now.
When not welding, we use it as a workbench we
can keep close to our project. The thick steel top
can take a beating and there are several different
clamps available that interface with the tabletop.
You can quickly and easily check the condition

of wheel bearings on almost anything. Safely raise
the vehicle, grab the tire at the 12 and 6 oclock
positions and check for slop. Any movement will
indicate that the bearings need to be serviced,
tightened, or replaced. However, make sure the
movement is coming from the bearings. On a
frontend application, worn ball joints will also
cause sloppy looseness.
3. Smooth Operating
When installing your own suspension at home,
dont gun down all the mounting hardware with
the vehicle in the air. Leaf spring bolts, shock
mounts, and link hardware should be left somewhat loose until you set the vehicle on the ground
where they can be tightened to proper spec. This
keeps the bushings from being bound up and
providing a stiff ride.
fourwheeler.com
4. Off-Road Stereo
7. Leak-Free Extension
Tired of mud, water, and dust destroying the

CD player in your 4x4? Switch out to a simple waterproof boat head unit like this Dual MGH30BT
Marine digital media receiver with built-in Bluetooth from Crutchfield (crutchfield.com). It takes
up a lot less space and can play all the music
stored on your phone.
The dipstick/caps on GM Saginaw power

steering pumps are notorious leakers. Adding a
short section of 112 -inch hydraulic or fuel hose
and a billet cap from Pro-Werks (pro-werks.com)
not only allows slightly more fluid to be added to
the system, it helps control power steering fluid
leakage.
5. Rattle Gun
8. Anti-Wrap
Planning on painting your entire 4x4 with rattle

cans? Do your fingers a favor and get your hands
on a spray handle like the Krylon Snap & Spray
(krylon.com). Youll be able to lay the paint more
evenly over a longer period of time with far less
finger fatigue.
Need to move the spring perches or change

the pinion angle on your leaf-sprung 4x4?
Consider using these extra-long perches from
RuffStuff Specialties (ruffstuffspecialties.com).
They are much beefier than factory perches and
a bit longer to help control axlewrap.
9. Chaser
Powdercoated beadlock wheels often have
paint in the locking-ring threads. It would take forever to chase them out with a tap by hand. Carefully using a low-power 38 -inch drill loaded with
the proper tap speeds up the process immensely.
Start slow and keep the drill straightyou dont
want to cross thread your new wheels.
10. Slick Rod End

Speaking of anti-seize, its a good idea to
smear it on tie rod and rod end threads to prevent
corrosion, which can make adjustment and
replacement a real pain down the road.
11. Trailer Checking

6. Seized No More
Protect your expensive beadlock wheels from damage caused by galling, dirt, and corrosion. Antiseize and beadlock bolts go together like bacon and pretty much anything. Reapply anti-seize to the
locking-ring bolts every time you remove and reinstall them.
fourwheeler.com
There are really only three common failures

on trailers. This includes wiring, tires, and
wheel bearings. On a road trip, check the hub
temperature of each trailer wheel. If one is hot
or warmer than the others, you could be losing a
wheel bearing. Keep in mind that trailer axles with
brakes will have significantly warmer hubs than
non-braked axles.
TECH 101 CHEAP TIPS & PROBLEM SOLVERS
15. Templated
12. Axle Adjustment
If you are getting the RuffStuff Specialties
perches to alter the wheelbase of your 4x4 a bit,
you might as well get the whole spring perch,
plate, and U-bolt kit for a clean and easy installation. The kit allows the axle to be moved 1-inch
forward or rearward from center.
When fabricating patch panels and other steel

plate brackets, use cardboard to first make a
template. Its far easier to fit up and trim the paper
with scissors than it is to grind steel. Transfer the
final template shape to the steel plate for cutting.
16. Third Hand

13. Twin Sliced
Making several steel brackets exactly the same
shape and size can be a near impossible task
without an expensive trace-cutting table. Tack
welding or bolting several rough-cut brackets together prior to grinding them smooth will provide
you with identical brackets on the cheap.
Mocking up steering and suspension components so you can get a better look at the big
picture under your 4x4 will save you a ton of failed
fabrication mistakes. Use heavy-gauge wire to
hang the links, steering, track bars, and other
components from the frame and axles. This gives
you the ability to easily move the components
around to check for fitment prior to making templates and cutting out brackets.
17. Cookie Cutting

If you are having difficulty making or seeing
cut lines on steel plate, use a bright-colored spray
paint to create a more contrasting line around
your cardboard template. This is especially helpful
when using a hand-held plasma cutter, which
requires a darker lens than some other cutting
methods.
18. Spatter Shield

Even the lightest weld spatter can destroy a
shock or steering ram shaft. When mocking up
these components with weld-on brackets, protect
them from dings and weld spatter with a layer or
two of masking tape.
19. Straight Tabs

14. Prefab
You can waste a lot of time and effort cutting out and smoothing common weld tabs. There are
lots of off-the-shelf tabs available from companies like RuffStuff Specialties and A&A Manufacturing
(aa-mfg.com).
Once mounting tabs are tack welded in place,

remove shocks, stabilizers, and ram-assist cylinders prior to finish welding. The heat can damage
these components. Use old hardware to keep the
tabs in place while welding. The weld heat can
cause them to warp, forcing the mounting holes to
be misaligned.
fourwheeler.com
23. Hammer Home
26. Slick Safety
Keep several different sizes of short sections of

tubing and old sockets around to help seat hard
to access seals and bearing races with a hammer.
Proper distribution of the load will set seals in
place without bending the sheetmetal body and
ruining the seal.
Always smear a little grease on the sealing

surfaces prior to installing a new seal, yoke, or
other similar component. The grease will help
keep the seal from being cut by splines and other
sharp machined edges.
21. Go-To Grinder
24. Common Leaker
27. Bottoming ID
When fabricating and 4x4 building in the

garage, there are few tools that get as much use
as our 412 -inch angle grinder. You can use it to
grind away and shape material, cut, and sand
items smooth. Many different wheels are available
for a multitude of jobs. We always keep a good
assortment on hand.
Driveline yoke splines can be an oil-leak spot.

Some newer applications include rubber gaskets
for sealing. You can seal up older yokes by smearing silicone on the splines prior to installation.
Do you know if you are over-compressing your

shocks? If you are, you could damage the shocks
or tear off the shock mounts. Use a zip tie around
the shock shaft to help identify how far the suspension compresses and if you need to relocate
your bumpstops.
20. Spray Sealing

For machined non-gasketed sealing surfaces,
like between the adjustment shims of a Dana 20
or Spicer 18, use something similar to Permatex
(permatex.com) Spray-A-Gasket Sealant. It goes
on easier and comes off cleaner than silicone in
these tight-fitting applications.
22. Rust Repellant

Front axles are extremely susceptible to rust,
especially in the wet states. Spindles and unit
bearings have a light press fit into the knuckle.
Corrosion can make removal near impossible.
When slapping your axles back together, smear
some anti-seize on the mating surfaces. Youll be
glad you did next time around.
fourwheeler.com
25. Weld Planning

Getting a consistent weld bead takes time and
practice. It also requires a bit of planning. Before
you try and throw down a weld, cycle the gun
from one end of the joint to the other in a dry run
to make sure you are in a comfortable position
and that there are no obstructions.
28. More Weld Planning

Weld joints should be good and tight prior to
finish welding. Gaps will make the joint weak.
But dont stop therePlan where the tack welds
should go. Place them in the middle or at the end
of a planned weld, never at the beginning. That
way you avoid stacking a cold start weld on top of a
tack, which creates an ugly globular appearance.
29. Flush Lighting
32. Clean Trimming
34. Simple Stoppers
Replacing busted taillights can get expensive.

If your 4x4 has flat panels in the rear, consider
some of these inexpensive flush-mounted truck
taillights. Most auto parts stores carry them. All
you need is the correct-sized hole saw, jig saw, or
body saw to get them in place. LED and traditional
bulb versions are available.
Trimming your fenders is an easy way to make

more room for bigger tires. Protect your 4x4s
paint from the foot of your preferred cutting tool
by layering masking tape over the foot, as well as
on the body prior to making the cut. The tape can
also be used as a planning tool to help you imagine what it will look like where you plan to trim.
Foam bumpstops are incredibly durable and

a lot less harsh than most rubber and urethane
bumpstops. GM PN 15712438 (right) can be used
as a good solid universal bolt-on bumpstop to fit
many applications. You can find them on the rear
of 99-06 Chevy Silverado 1500 pickups, among
other vehicles. They run about $20 each new.
33. Rod End Remedy

30. Cut and Fold
Removing metal can weaken the unit body of
some 4x4s. Rather than cutting out inner fender
material, consider slicing and folding over the offending bits. This will actually help strengthen the
body in some areas.
If using rod ends in a single-shear application,

like on a tie rod or drag link, install safety washers.
These will help keep the joint together in the event
the ball is pushed out of the body of the rod end.
Companies like Synergy Manufacturing (synergymfg.com) offer radiused safety washers that do
not limit movement.
35. Camp Power

Even if you are into primitive camping, a small
portable generator can be incredibly handy to
recharge batteries, run electric tools to make
repairs, and so on. Small generators are more
affordable than ever and they are much quieter
than earlier versions.
36. Handy
Help
31. Tube Fitting

Plan on working with tubing? Get your hands
on a tubing notcher like the TN-100 from JD
Squared (jd2.com). It makes fish-mouth cuts in
tubing using common hole saws and is powered
by your 12 -inch drill. Its quicker, cleaner, and
more precise than using a grinder.
Ratchet straps are

incredibly handy when
doing tube work on
rollcages and seat
mounts. The straps
can be used to hold
everything in place
while you tack weld
the joints. Use cheapie
straps because weld
spatter tends to make
a mess of the nylon
webbing.
fourwheeler.com
BAJA MTZ
P3
is an incredible mud terrain tire that has

been specially designed with a unique silica
reinforced tread compound for longer wear,
enhanced wet weather capability, and
superior cut and chip resistance.
SHOP, COMPARE, SAVE.

Click the Buy Now button at
MickeyThompsonTires.com.
NEW M/T METAL SERIES WHEELS & DEEGAN 38 WHEELS AVAILABLE!

MM-245
CLASSIC III BLACK
BAJA ATZP3
MM-366
SIDEBITER II
BAJA MTZP3
MM-489
DEEGAN 38 PRO 4
BAJA CLAW TTC
For a dealer near you, 866-943-7177 MickeyThompsonTires.com
DEEGAN 38 PRO 2
NEW
BAJA STZ
CLASSIC III
NEW
CLASSIC BAJA LOCK
MM-164M
NEW
MM-164B
DEEGAN 38
37. Mobile Speedo

If youve swapped tires and axle gearing,
then you probably have no idea how far off your
speedometer is. There are several free iPhone
apps that can help you figure it out via a GPS
speedometer. The apps usually have other useful
functions as well.
40. Weld Power

Battery cables come in many lengths and gauges, but sometimes exactly what you need isnt available. Welding cable (far right) is able to handle high-amp loads and can be bought by the foot from your
local weld shop. Its perfect power cable for custom-length applications.
38. Spare Carrier

Use the correct axlehousing end to build a
spare flanged axle carrier. You can even find a
seal for the backside to keep the axle bearing
clean and lubed with grease. Spray paint the
shaft and splines to prevent corrosion.
41. No Fun Flat
43. Corroded Cables
Got some old project languishing in the yard

with leaky tires, yet you still need to move it
around occasionally? We have successfully used
Slime (slime.com) to seal up rotten tires that have
long since given up safe use on the street. It
might save you from buying a new set of tires for a
rolling parts 4x4.
Corrosion on your battery terminals can

cause hard starting and unpredictable electrical
gremlins. A cup of water with a bit of baking soda
stirred in will quickly and easily remove this mess
and neutralize the leaked battery acid. Remove
and scrub the terminals with the mixture for best
results.
39. Cheapest Fuel

When driving through a new area you never
know which gas stations are out to gouge you.
Now you can find out with the Gas Buddy iPhone
app. It maps the fuel stations closest to you and
provides the price per gallon of your selected fuel.
The information is constantly updated by other
app users.
42. Bad Bet

Save your money. Dont ever bet John Cappa
he cant drink a pint of mustard in under a minute. You will lose that bet and probably get sick
watching him take your money and laugh.
44. MacGyver Funnel

There is never a funnel around when you need
one. Or is there? Plastic soda, water, and even oil
bottles make perfect disposable funnels when
you remove the cap, cut out the bottom, and flip
it upside down.
fourwheeler.com
45. Frame Straightener

A Hi-Lift can be incredibly handy in the shop
too. Weve even used one to straighten out a
bowed frame by clamping the two rails together.
Creative users might even be able to correct a
diamond-shaped frame with a Hi-Lift and a few
chains.
48. Hosing
51. Smooth Sealing
It seems like common sense but hose the

mud, cow dung, and dead animals off of the underside of your 4x4 before going to work on it. No
one likes a clump of mud or dead skunk landing
on their forehead during an oil change.
Sometimes even new parts have burrs and

inconsistencies that can cause leaks in critical
areas. Inspect holes for burrs and smooth them
prior to installation. Used parts can be suspect as
well if they were improperly installed.
49. Power Hider

46. Stay Put
Spicer-style axleshafts can sometimes spit
out their U-joint caps under heavy stress. If you
plan to abuse your stock axles, consider tack
welding the caps to the axleshafts. Its not a good
permanent fix. You need stronger shafts, but in
most cases it can get you through the weekend if
you catch the caps wobbling and pushing out of
their bores.
Sometimes there just isnt enough room for a

car battery under the hood. The fact of the matter
is that the battery will likely last longer if you can
get it away from the temperature changes found
in an engine bay. Think outside the box when
mounting your battery. In this case, a rear wheelwell worked perfect.
52. Infestation
Extermination
Has your garage been invaded by small
rodents? Try building a bucket trap. Run a bit of
wire over the top of a 5-gallon bucket. Thread on
a peanut butter-coated spindle in the middle and
put about 4 inches of water in the bottom of the
bucket. Mice will try to climb out onto the wire
to get at the food, fall in the bucket, and drown.
Make sure there is a ramp for them to reach the
top of the bucket. You may need a garbage can
or something bigger for larger rodents like rats,
squirrels, and hipsters.
47. Lifting
50. Bead Buster
53. Shimmy
Need to do a body swap or lift a heavy object

and your buddies are conveniently never around
when you need them? Build a gantry crane. You
can also purchase rolling gantry cranes from tool
suppliers like Harbor Freight (harborfreight.com).
A deflated tire can be easily unseated from the

bead for repair or removal with the use of a heavy
4x4 and a Hi-Lift jack. You may need to work your
way around with some soapy water if its a tightfitting tire-and-wheel combo.
Whenever possible, we prefer to use pinion

shims instead of crush collars when regearing a
4x4. Weve seen off-road abuse cause issues with
crush collars. Shim kits are available for some of
the more popular axles like the Ford 9-inch.
fourwheeler.com
54. Chalk It Up
Use chalk across the tread of your oversized
aftermarket tires to help figure out what air pressure you should be running on-road. Pull forward
in a straight line for 50 to 100 feet on a smooth,
level, paved driveway or parking lot. If the chalk is
worn on the outside edges of the tire, add more
air. If the chalk is worn away in the middle only,
deflate the tire a few psi. Reapply the chalk and
perform the procedure several times on all four
tires until you get even wear of the chalk across
the entire tread surface.
59. Correct Temp

57. Four-Link Fab Tip
On a properly built triangulated four-link
suspension, the most wear-prone joints are on the
top links. Not only are they controlling the torque
applied to the axlehousing by the engine, they are
also keeping the axle from moving laterally. These
upper joints should be just as beefy as the lower
arm joints in order for them to last a long time.
Pay special attention to where you mount the

water temperature sensor on your engine. We
have seen many gauges read hot when the sensor is placed in the head too close to an exhaust
port. To get a proper reading, the ideal location is
near the water outlet headed to the radiator.
60. Brake Bound

55. Temporary Tap
58. Spunout
You may not always have the correct tap to

chase out some dirty threads. Slice a groove into
the proper-sized bolt with a cutoff tool. Clean
the threads up with a nut or file and you have a
makeshift chase tap. Dirt and gunk will collect
in the groove as you thread the chaser into the
threaded hole.
Once a wheel bearing race spins out inside

a wheel hub, the hub is ruined. You can get just
a bit more life out of the hub by distorting the
bearing seat surface with a punch. This is only a
temporary solution until you can locate a replacement hub.
We have yet to find a brake line wrench that

works every time. So far, the best tools we have
found for removing stuck brake lines without
damaging them are the Craftsman (craftsman.
com) Adjustable and Knipix (knipex-tools.com)
pliers.
61. Pinch Punch

56. Chain Gang
Keep a couple short sections of chain and a few bolts in your 4x4 trail repair box. You can use the
chains to lash a steering box back to the frame, keep high-steer arms with busted studs in place, stabilize a broken motor or transmission mount, and more.
You should have the correct large-sized socket

for your traditional serviceable wheel hubs. If you
dont, you can sometimes use a punch or chisel
and hammer to loosen and tighten the hub adjusting nuts. Then head to the store for the proper
tool, ya hack.
fourwheeler.com
65. Platform Pounding

62. Garage Alignment
Setting the toe on a solid axle 4x4 can be easily
done with a tape measure and a straight circumferential line around each front tire. Measure
from the front and back side of the tires. The tires
should be towed in 0- to 38 -inch in most cases.
Replacing a U-joint at home isnt exactly fun,

and replacing one out on the trail without a vise or
hard flat surface is downright hateful. Toss a 1x1foot or similar sized sheet of aluminum into your
trail toolbox to be used as a mini work station. The
flat plate will give you a solid platform to pound
the new U-joint into place in no time.
63. Spill-Free Filling
66. Gas Grommet
Brake fluid does bad things to paint. We always

seem to spill it when pouring with an open top. To
keep this from happening, we use a gear oil bottle
top and a small section of hose to direct the fluid
exactly where we wantin the master cylinder
and not all over the paint.
Cant find the correct rubber grommet to

protect the wires passing through the firewall? No
worries. Split a short section of fuel hose down the
middle and push it into place around the sharp
edges of the hole.
67. Strap On
Reseating a popped tire bead can sometimes
seem like an impossible job. Troublesome tires
can be coerced with a ratchet strap around the
center of the tread area. Clean the tire bead and
wet it. Start filling the tire with air and quickly
loosen the ratchet strap as soon as you see
the tire catch and hold against the wheel bead
surface.
68. Oil Dam

Factory and aftermarket skidplates often fill up
with oil when performing an oil change on your
4x4. Use masking tape to help direct the flow of
the draining oil down into the drain pan instead of
allowing it to make a mess.
69. Sealed Electricals

64. Handled Steering
Your Hi-Lift jack handle can be used to straighten and strengthen a bent tie rod, draglink, or track
bar. Simply straighten the offending component as best you can and slide the tube in place to get off the
trail. Replace the bent bits with the proper new parts as soon as possible.
fourwheeler.com
Worried about your electronics getting wet

when wheeling? Place the components in a
Tupperware container on the firewall. Seal the
holes for the wires with silicone. Install the cover
when you plan to hit deep water.
75. Pre-Soak
70. Track Bar Tackle
Manhandling an axle around to install a track bar can be simplified by the use of a ratchet strap.
Simply attach one end of the strap to the axle and the other to the frame. Ratchet the axle into place so
the boltholes line up.
If you plan to install your own lift kit, swap

axles, or do any other sort of undercarriage work,
soak the hardware with penetrating oil for a
couple days prior to spinning any wrenches.
This will make removal go much smoother in
most cases.
71. HREW vs. DOM vs.

Chromoly
The most cost-effective structural tubing for
rocker guards, rollcages, and bumpers is 1026
DOM. Its about twice the strength of typical
HREW tubing. In most cases 4130 chromoly is
only about 10 to 20 percent stronger than DOM;
however, to achieve that strength, it needs to be
heat treated after welding. This is not something
you can really do in the garage. Chromoly tube is
also significantly more expensive than DOM.
73. Chafe Saver
72. Radiator Condom
74. Fitting Fittings
77. Matching Bolts
The first thing you should do with a new

radiator is cut up the box it came in and use the
cardboard to protect the core front and back.
Radiators often get inadvertently banged around
during installation, and the last thing you want to
do is damage it.
The cost of aluminum AN race fittings can add

up quick. If you dont mind the added weight,
you can use common steel AN or JIC fittings that
you can find at any hydraulic shop. These steel
fittings are about a third of the price of aluminum
AN fittings.
Multi-colored bolts all over your project can

make it look sloppy. Bolt heads can be easily
painted to match by pushing them through cardboard and painting them the desired color. Its
also a good way to keep the bolts organized when
pulling something apart.
Protect high-amp wiring from being chafed

and shorting out by slipping old heater or garden
hose over the cable in suspect areas. Use zip ties
to keep the hose in place if its not a tight fit. Stubborn cables will slide through more easily if you
wet them with window cleaner or silicone spray
prior to pulling them through.
76. Your First Welder

Buying your first welder? Buy more machine
than you think youll need at first. That way you
can grow into it and not have to buy twice when
your projects become more complex and involved
down the road. Weve never seen anyone ever
need less welder capability and duty cycle performance as their skills develop.
fourwheeler.com
83. Wedgie
Weve always liked using this compact ORI
urethane spare tire wedge (PN 99-4440) when
building a spare tire mount for the bed of a pickup
or other 4x4. Several different companies sell this
type of mount.
78. Clearance Slave

Most clutch slave cylinders are a push type, the problem is that they can often interfere with the
exhaust routing. This Wilwood (wilwood.com) pull-type slave cylinder (PN260-1333) offers lots of adjustability and can be installed out of the way of most exhausts.
79. Containment
Plastic shipping stretch wrap is extremely
handy when storing greasy components you want
to keep dirt free. Birfield and Rezeppa joints,
transmissions, transfer cases, axles, and more
can be sealed up keeping dirt and gunk out and
the greasy oily mess in.
81. Wire Fishing
84. Lug Locked
If you need to run wires through a rollcage,

bumper, or frame, do what any electrician would
do. Greenlee (greenlee.com) offers several fish
tape tools to help pull wire and even fuel lines
through tight spaces.
The best way to keep your wheels and tires on

your truck and out of the hands of thieves is to
use two different types of wheel locks. Also, dont
leave the lug lock keys in obvious hiding spots like
the center console or glovebox.
80. Bolt Bins
82. Spring Brake
85. Keep Capped
We use large square plastic pickle containers

to organize loose hardware by size. We can always
easily find the exact bolt or nut we are looking for,
rather than sifting through one large container
with every size stuffed in it.
Brake lines can often get wrapped up into

bumpstops, steering components, tires, and
shocks where they can be torn or chafed. You can
keep them safely away from other components by
using a few light throttle return springs.
U-Joint caps can fall off when you remove a

driveshaft, causing the needle bearings inside to
get lost in the dirt or on the shop floor. Use electrical tape to keep the caps in place when storing a
driveshaft.
fourwheeler.com
89. Coin Cutting

86. Tow Tech
The absolute strongest way to attach a tow
point is to cut a hole and weld the mount on the
front and back side. Thick materials should be
preheated for proper weld penetration.
Its hard to beat the precision of an air saw

when cutting fenders and other body metal bits.
Unfortunately, the blades can be expensive.
Hacksaw blades can be broken down into 2 to
3-inch sections and used in an air saw for far less
money than the actual blades.
87. Conspiracy Welder
90. Free Air
An OCD fabricator we know swears he gets a

cleaner weld start when he cuts off the melted tip
of the filler wire before starting a new MIG bead.
He does this every time. You can try it for yourself
and see if you agree.
The absolute fastest way to air down your tires

is to simply remove the valve core. There are lots
of low-cost tools available to perform this task.
Carry spare valve cores because you will eventually lose one in the dirt.
91. ECM Clamp

Binks Fabrication (binksfab.com) offers these
trick ECM mounts for GM engine computers.
They are perfect for anyone making an engine
swap with GM EFI.
92. Wire-Feed Pliers

If youre using a MIG or flux-core welder, you
need a pair of USA-made Channellock (channellock.com) 360 9-inch Welders Pliers. They are
designed specifically for use on wire-feed welders
to help accomplish all of the common tip cleaning,
tightening, and cutting tasks.
93. Faded Fenders

88. Fuel Starvation
Tall narrow fuel cells are better for off-roading. Fuel slosh is less likely to cause starvation than on
short wide fuel cells when crawling over obstacles at all angles.
Weve seen Binks Fabrication use a MAPP gas

torch to lightly heat-faded plastic TJ fender flares
back to black. A heat gun is said to work too but
not as quickly. Watch the paint and dont light
your Jeep on fire. Remove the flares first. And we
thought it was only good for burning spiders in
the garage.
fourwheeler.com
99. Twitchy Throttle Fix

94. Beat Detector
A quick way to tell if a used 4x4 has been abused off-road is to take a look at the undercarriage.
Dents and deep scrapes are clear signs that a 4x4 has been used hard off-road. If youre looking for a
clean daily driver, look for a clean undercarriage.
95. $1 Car Alarm

The best way to keep someone from stealing
your 4x4 is to keep them from starting it. Install
a hidden switch that shuts of the fuel or ignition.
Clever electricians can wire the switch to sound
the horn when a thief tries to start the engine.
97. Waterproof
Everything
There are many different ways to waterproof
the vital components of your engine. We have
had great luck with K&N (knfilters.com) Air Filter
Sealing Grease (PN 99-0704). Its really thick and
gooey. Weve used it successfully on air filters,
around the distributor cap, dipstick tubes, and on
oil filler lids.
96. Universal Tube

Bushings
98. Budget Bleeder
Wrangler YJ leaf spring bushings have a 1.25inch and 1.50-inch diameter so they fit into 1.5inch, 0.120 wall and 1.75-inch, 0.120-wall tubing,
respectively. The bushings are perfect for custom
motor and transmission mounts as well as many
other uses. They can be trimmed and drilled to fit
lots of applications.
One-man brake bleeding is easy with a brake

bleeding bottle. Build your own with a small
lidded container and short section of hose that
fits over the bleeder screw. You can push caliper
pistons back into their bores with a C-clamp or
large pliers when installing new brake pads and
flush out the old fluid at the same time.
fourwheeler.com
Got a throttle pedal thats twitchier than the

hair trigger on a buffalo gun? Edelbrock (edelbrock.com) offers a linkage extension (PN 8012)
that allows you to ease into the fuel. The bracket
fits popular carburetors and some throttle bodies.
100. Bumpstop Struggle

Sometimes urethane bumpstops just dont
want to pop into their cups. A little silicone spray
and small bottle jack gets them in every time. Just
make sure the axle is properly supported.
101. Bumper Unbasher

Plastic bumpers and trim bits can sometimes
be bent back into shape with the help of a heat
gun. Crushed components like this bumper end
may need a little coercing from the inside out.
Drilling an inconspicuous hole on the backside
will give you access to the dent. fw
FEATURE
Modern Power with Classic Style

By Harry Wagner
editor@fourwheeler.com Photography: Harry Wagner
T KIND OF GOT OUT OF HAND, BLAKE
van Brouwer explained when

describing his three-door 71
Suburban. Originally he just
wanted a 4x4 that he and his family could
use to explore the mountains around their
home in Reno, Nevada. Not just any 4x4
would do, thoughIt had to be a vintage
Chevy. So when Blake found a three-door
Suburban that was someone elses halfdone project, he snatched it up for cheap.
It took a diehard Bow Tie fan to see the
potential in the Burb, given the hacked
interior and purple metalflake paint job.
It wasnt just ugly. It was a poor paint
job, Blake recalls. That made it easy for
Blake and his friend Tony Faraco to start
over though.
Rather than cutting and hacking the
Suburban to mount a cage or 44-inch-tall
tires, Blake spent his time making the
Suburban more reliable and comfortable. I actually used a lot of stock parts
from various applications, he confessed.
This saved a lot of money compared to
using aftermarket parts for everything.
Of course you cant just slap a Pontiac
Aztec grille on the front of a Suburban
and call it custom. Blake sourced a 6.0L
Gen III engine from a late-model 34-ton
Chevy pickup to repower his Suburban.
The 4L80E overdrive transmission and
NP261HD chain-driven transfer case were
also sourced from the same truck so no
expensive adapters or additional electronic
control modules were necessary.
The front axle is an 8-lug Dana 44
out of a Ford F-250. This is a driver-drop
axle, which matches up with the output
of the NP261 transfer case and, also as
THREE-DOOR
THUNDER
fourwheeler.com
Rolling stock consists of 13/38-16LT Super Swamper

TLSs mounted of factory Ford 34-ton wheels that have
been powdercoated gloss black by Marq Powdercoating. The narrow tire and wheel combination look
perfect under the vintage Suburban and tuck nicely
into the fenders during articulation.
fourwheeler.com
FEATURE THREE-DOOR THUNDER

a bonus, uses a high-pinion design that was
never offered in a Chevy. The high-pinion is
both stronger (when used in the front) and also
decreases the angle of the front driveshaft,
thus limiting vibrations. The same axle was
used in F-150 pickups as well, but with coil
springs, radius arms, and a 5-lug bolt pattern
that would not work with Blakes leaf springs
and 8-lug rear axle. That axle is the mighty
GM 14-bolt, with a huge ring gear and threepinion bearings to eliminate any chance of
gear deflection. Plus, the 14-bolt fits the theme
of getting more bang for your buck.
The interior was completely restored, right
down to the powdercoated door strikers and
seat brackets. The exterior received similar
attention, something rarely seen on a wheeling
rig. In fact, that is what Blake meant when he
said things got out of hand. Now the Suburban is almost too nice to wheel! Blakes solution for that, though, was to purchase a 72
K5 Blazer. With the same great vintage looks
as the Suburban but with old, faded paint,
Blakes plan is to add 1-ton axles and just head
for the hills, dents and scratches be damned.
4
1. A modern 6.0L V-8 powers the Suburban. The
engine has been enhanced with a Comp Cams RV
camshaft, Spectre intake, Doug Thorley headers, and injectors and MAF from an 8.1L truck. A
Painless wiring harness was used to ease the heart
transplant.
2. Blake retrofit hydroboost brakes onto the Suburban with a custom bracket that he built himself.
Otherwise, the brakes use all factory, off-the-shelf
parts. This kept the cost down compared to custom one-off parts, he explained. Plus, parts are
easier to find in the middle of nowhere, should you
ever need them.
3. The aluminum crossflow radiator is from Summit
Racing. Even without a fan shroud, the dual 1,350cfm electric fans have no problem keeping the
engine cool. Blake has another truck with a 6.0L
in it and was able to use that to help mock up the
wiring and hose routing.
4. Even with a huge cabin and lots of glass, the
Vintage Air unit keeps the Suburban cool on toasty
days. The A/C is cleanly routed, and the controls
dont look out of place at all on the dash. The
compressor runs off the same serpentine belt as
the rest of the accessories.
5
5. When Blake purchased the Suburban, it had a

horrible purple metal flake paint job and the dash
had been hacked to fit a touchscreen. Fortunately,
he saw past all of these issues and was able to
tastefully restore the interior with a recovered stock
seat and new marine carpet by Economy Upholstery
in San Diego. Dolphin gauges monitor the engines
vital signs and the 4L80E transmission is shifted
via a column shifter on the rebuilt factory column.
The Kenwood stereo, Infinity speakers, and Vintage
Air A/C add modern conveniences without looking
out of place.
fourwheeler.com
10
6. The rear of the Suburban fits a fullsize spare tire

and Hi-Lift jack, with plenty of room for camping gear,
ice chests, or whatever Blake wants to haul along. The
back seat is a rare 70/30 split from a 74 Suburban. It
folds flat to provide even more cargo space.
7. Details like the gas struts on the rear doors are
items most four-wheelers would overlook, but they
really set this Suburban apart. Blake also retrofit
power windows from a 70s Suburban into the
three-door and made his own wiring harness for the
windows, but you would be hard pressed to tell that
they are not original.
AT A GLANCE
GENERAL
Vehicle: 71 Chevrolet Suburban

Owner: Blake van Brouwer
Stomping grounds: Reno, Nevada
Build time: Six months
DRIVETRAIN
11
8. The front axle is an 8-lug Dana 44 with 34-ton

brakes and dual Rancho steering stabilizers. It is
a high-pinion, driver-drop axle out of a Ford F-250
that matches the front output yoke location to
the NP261HD transfer case. The entire axle was
rebuilt with new bearings and seals, along with
MileMarker hubs and deeper 5.13 gears to work
in conjunction with the 38-inch-tall tires and
overdrive transmission.
10. The rear suspension uses F-250 leaf springs

and greasable shackles that combine with Rancho
RS9000 adjustable shocks to provide approximately 5 inches of lift. Note how the brake lines
are neatly routed and the U-bolts face upward to
keep from getting caught on obstacles. Between
the springs, the cross-linked polyethylene gas tank
holds 20 gallons of fuel.
9. The front suspension uses F-250 leaf springs on

custom outboarded hangers with greasable shackles and Rancho RS9000 adjustable shocks. While
not as fancy as coil springs or coilovers, these leaf
springs arent exactly archaicThey use several
thin leaves to provide a very progressive spring rate
that rides quite nicely.
11. The rear axle is a GM 14-bolt with 5.13 Yukon

gears and disc brakes that use Ford E-350 van
calipers. With a 1012-inch ring gear, third pinion
bearing, and 112-inch axleshafts, these axles need
few upgrades to withstand big power. The huge
4-inch aluminum driveline was sourced from a 98
GM K3500. fw
fourwheeler.com
Engine: 6.0L V8
Transmission: 4L80E four-spd automatic
Transfer case(s): NP261HD
Low range ratio: 2.72:1
Crawl ratio: 34.6:1
Front axle/differential: Dana 44 w/ 5.13 Yukon gears
and MileMarker hubs
Rear axle/differential: Corporate 14-bolt w/ 5.13
Yukon gears and disc brakes
SUSPENSION
Front: Custom leaf springs with Rancho RS9000
shocks
Rear: Custom leaf springs with Rancho RS9000
shocks
Steering: Crossover steering with 2WD power steering
box and drop pitman arm
TIRES/WHEELS
Tires: 13/38-16LT Super Swamper TSL
Wheels: 16x7 Ford factory steel
MISCELLANEOUS
Armor: Rechromed factory bumpers, 10-ton eyebolts
Cool stuff: Restored interior, Gen III power, air conditioningall of the little details!
QUALITY TOOLS
R
PE ON
SU UP
O
C MECHANIC'S GLOVES
SIZE
MED
LG
X-LG
SUPER COUPON
LOT
COMP AT
62434/62426 $12.74
62433/62428 $12.38
62432/62429 $11.99
YOUR CHOICE
$ 99
Item 62429 shown
SAVE
UP TO
68%
LIMIT 6 - Good at our stores or HarborFreight.com or by calling

800-423-2567. Cannot be used with other discount or coupon or prior
purchases after 30 days from original purchase with original receipt.
Offer good while supplies last. Non-transferable. Original coupon must be
presented. Valid through 4/11/16. Limit one coupon per customer per day.
R
PE ON
SU UP
CO
RETRACTABLE
AIR HOSE REEL WITH
3/8" x 50 FT. HOSE
LOT 93897 shown
69265/62344
SAVE
$106
4-1/2" HEAVY DUTY

ANGLE GRINDER
LOT 60372/91223 shown
SAVE
39%
17
99
comp at
$29.97

R
PE ON
SU UP
CO
Limit 1 coupon per customer per day. Save 20% on any 1 item
purchased. *Cannot be used with other discount, coupon or any
of the following items or brands: Inside Track Club membership,
extended service plan, gift card, open box item, 3 day parking lot sale
item, compressors, oor jacks, saw mills, storage cabinets, chests
or carts, trenchers, welders, Admiral, CoverPro, Daytona, Diablo,
Franklin, Hercules, Holt, Jupiter, Predator, Stik-Tek, StormCat, Union,
Vanguard, Viking. Not valid on prior purchases. Non-transferable.
Original coupon must be presented. Valid through 4/11/16.
WOW
8 CHANNEL
SURVEILLANCE DVR
WITH 4 INFRARED CAMERAS
30", 5 DRAWER
TOOL CART
Customer Rating
comp at
Customer Rating
DRIVE
1/4
3/8
1/2
704 lb. Capacity
$16999
$

ADJUSTABLE STEEL
WELDING TABLE
Customer Rating
1199
SAVE
83%
UP
TO
SUPER
COUPON
2.5 HP, 21 GALLON Customer Rating

125 PSI VERTICAL
AIR COMPRESSOR
LOT 67847 shown
61454/61693
62803/69091
SAVE
$349
14999
comp at
R
PE ON
SU UP
CO
99
SAVE
$90
$399.99
5999
comp at
$149.99
SAVE
33%
LOT 69606/61173
68099 shown
SAVE
$109
3999
comp at
$149.88

R
PE ON
SU UP
CO
42" OFF-ROAD/
FARM JACK
Customer Rating
1/2" ELECTRIC
IMPACT WRENCH
Customer Rating
32 PIECE
SCREWDRIVER SET
LOT 61259/90764 shown
LOT 60668/6530 shown

LOT
61369
$499

Item 239
shown

R
PE ON
SU UP
CO
WOW
COMP AT
$29.99
$54.91
$73.22
YOUR CHOICE
$349.99
R
PE ON
SU UP
CO
LOT
2696/61277
807/61276
239/62431
Customer Rating
18999
comp at
TORQUE WRENCHES
Accuracy
within 4%
SAVE
$180
SAVE
$140
259
WOW
SUPER
COUPON
LOT 95272 shown

69397/61427
LOT 62463/61624
61229 shown
Over 2500
hours of
recording
time.
We have invested millions

of dollars in our own
state-of-the-art quality test
labs and millions more in
our factories, so our tools
will go toe-to-toe with the
top professional brands.
And we can sell them for a
fraction of the price because
we cut out the middle man
and pass the savings on to
you. Its just that simple!
Come visit one of our
600 Stores Nationwide.
SUPER
COUPON
$166

FULL LINE OF
GRINDING AND
CUT-OFF WHEELS
ANY
SINGLE
ITEM
5999
comp at
R
PE ON
SU UP
CO WE CARRY A
20%
OFF
How Does Harbor Freight

Sell GREAT QUALITY Tools
at the LOWEST Prices?
SAVE
59%
3-1/2 Ton
Capacity
Customer Rating
39
99
$ 99 $14comp.97at
comp at
$59.99




R
PE ON
SU UP
CO
R
PE ON
SU UP
CO SAVE
R
PE ON
SU UP
CO
R
6.5 HP (212 CC) OHV
PE ON
SU UP Customer Rating HORIZONTAL SHAFT
GAS ENGINES
CO
MECHANIC'S SHOP TOWELS

PACK OF 50
LOT 46163 shown
63031/69649
61878/61837
1195 LB. CAPACITY

4 FT. x 8 FT.
HEAVY DUTY FOLDABLE
$170
UTILITY TRAILER
SAVE
75%
LOW-PROFILE
CREEPER
300 lb. Capacity
LOT 69262
69094/61916
2745 shown
"
40
Customer Rating
SAVE
44%
$ 99
comp at
$18

DOT Certied
Tires
LOT 62170/62648/62666
90154 shown
25999
comp at
$429.99

19"
$1999
Tools sold
separately.
22999
comp at
$79.99

LOT 60363
69730/68120
LOT 68121
69727 shown
CALIFORNIA ONLY
SAVE
$228
9999
comp at
$328

LOWEST PRICES EVERYDAY
WOW
FREE
SAVE
$50
90 AMP FLUX
WIRE WELDER
No Gas Required
SUPER COUPON
Customer Rating
SUPER
COUPON
600 Stores
Nationwide
WITH ANY PURCHASE
1" x 25 FT.
TAPE
MEASURE
WE CARRY
A FULL LINE OF
WELDING WIRE
$99
99
LOT 69080 shown

69030/69031
LOT 61849/62719
68887 shown
109
$ 99
comp at
99$149.99
VALUE
LIMIT 1 - Cannot be used with other discount, coupon or prior purchase.

Coupon good at our stores, HarborFreight.com or by calling 800-423-2567.
Offer good while supplies last. Shipping & Handling charges may apply if not
picked up in-store. Non-transferable. Original coupon must be presented.
Valid through 4/11/16. Limit one FREE GIFT coupon per customer per day.
LIMIT 3 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot

be used with other discount or coupon or prior purchases after 30 days from original
purchase with original receipt. Offer good while supplies last. Non-transferable. Original
coupon must be presented. Valid through 4/11/16. Limit one coupon per customer per day.
WOW
R
PE ON
SU UP
CO
SUPER
COUPON
RAPID PUMP
1.5 TON
ALUMINUM
RACING JACK
Customer Rating
WOW
SUPER
COUPON
SUPER
QUIET
4000 PEAK/
3200 RUNNING WATTS
6.5 HP (212 CC)
GAS GENERATORS
Customer Rating
LOT 69729/69676 shown
LOT 69252/60569 shown

68053/62160
62496/62516
29 PIECE TITANIUM
NITRIDE COATED
HIGH SPEED STEEL
DRILL BIT SET
Customer Rating
SAVE
76%
LOT 5889/62281/61637 shown
13
99
comp at
$59.97

R
PE ON
SU UP
CO
AUTOMATIC
BATTERY FLOAT
CHARGER
LOT 42292 shown
69594/69955
SAVE
82%
$ 99
comp at
$34.99
LOT 69675/69728
CALIFORNIA ONLY
SAVE
$60
SAVE
$230
$5999
$
89
comp at
99 $119.99
3-1/2 Pumps Lifts

Most Vehicles
Weighs 32 lbs.
R
PE ON
SU UP
CO
12 TON
SHOP PRESS
LOT 33497
60604 shown
5999
comp at
$259.99
SAVE
$200
LOT 61258 shown

61840/61297/68146

R
PE ON
SU UP
CO
2 PIECE VEHICLE
WHEEL DOLLIES
LOT 60343
67338 shown
Customer Rating
SAVE
$50
1500 lb.
Capacity
SAVE
$80
9999
comp at
$179
R
PE ON
SU UP
CO
12 VOLT
MAGNETIC
TOWING
LIGHT KIT
SAVE
71%
LOT 62753/69925
69626/62517
67455 shown
Customer Rating
$ 99
comp at
comp at
$34.95

R
PE ON
SU UP
CO
10 FT. x 20 FT.
PORTABLE CAR CANOPY
LOT 60728/69034 shown
63054/62857/62858
SAVE
$79
LOT 61474
69229 shown
$109.99
$99.99

2999
comp at
4999
comp at
$529.99
WIRELESS WINCH
REMOTE CONTROL
Customer Rating
29999
LIMIT 4 - Good at our stores or HarborFreight.com or by calling 8

Pair of Arbor Plates Included
SAVE
$79
2500 LB.
ELECTRIC WINCH
WITH WIRELESS
REMOTE CONTROL
70 dB Noise
Level

R
PE ON
SU UP
CO
R
PE ON
SU UP
O
C Customer Rating
Customer Rating
11999
comp at



R
PE ON
SU UP
CO
R
PE ON
SU UP
CO
R
PE ON
SU UP
CO
56", 11 DRAWER
INDUSTRIAL QUALITY
ROLLER CABINET
56"
42"
SAVE
$1100
Weighs
441 lbs.
3458 lb.
Capacity
69999
LOT 69395/67681 shown comp at
$1799.99

SAVE
61%
72" x 80"
MOVER'S BLANKET
LOT 66537 shown
69505/62418
8", 5 SPEED
BENCHTOP
DRILL PRESS
Customer Rating
LOT 62520/62390/60238 shown
SAVE $
$ 99$17comp.97at $66
5999
comp at

R
PE ON
SU UP
CO
3 TON HEAVY DUTY

STEEL JACK STANDS
LOT 38846 shown
69597/61196/62392
SAVE
42%
$126.47

100% Satisfaction Guaranteed

No Hassle Return Policy
600 Stores Nationwide
Over 25 Million Satised Customers Lifetime Warranty On All Hand Tools HarborFreight.com 800-423-2567
$199
1999
comp at
$34.99

TECH
THINGS
YOURE
DOING WRONG
10
Correcting common 4x4 errors

By John Cappa
editor@fourwheeler.com Photography: John Cappa
E ALL TEND TO TAKE SHORTCUTS AND FIX THINGS THE WAY WE ALWAYS HAVE, BUT SOMETIMES
those shortcuts and ingrained methods are wrong and can make your 4x4 life more
difficult in the long run. It doesnt matter if youve been doing it wrong for years or
have only just started your bad habits; its easy to change once you realize there is a
better way. We compiled 10 of the more common mistakes made by off-road enthusiasts when
working on and operating a 4x4. Here is what you should and shouldnt be doing.
1. You Lug Nut

When was the last time you tightened your lug nuts in a star pattern or actually used a torque wrench
to seat them properly? Most of us simply bust out the impact gun, nail down a couple lug nuts until the
wheel is seated, and then go to
town gunning down the remaining lug nuts. Nine times out of
10, youll never have an issue.
It will be that one time when
a wheel sets itself free on the
highway at 60 mph that youll
have the urge to do it right. Lug
nuts should be slowly tightened
in a crisscross star pattern and
torqued to the proper specification. The proper torque will
depend on the vehicle. You
can find the exact torque for
your 4x4 on the Discount Tire
(discounttire.com) website. In
most cases the torque spec will
be based on the following wheel
stud sizes:
Lug Size
16 in
1
2 in
9
16 in
5
8 in
12 mm
14 mm
7
Lb-Ft Torque
55-65
75-85
95-115
135-145
72-80
85-95
2. U-Joint Smasher
So you loaded your fresh new driveshaft
and U-joints into the transfer case and axle
yokes of your 4x4, and then proceeded to
manhandle the wrench and unknowingly
smash the U-joint caps by overtightening
the retaining U-bolts. This will lead to shorter
U-joint life, but it may not matter if you let
your driveshaft bind at full droop and eventually break anyway. Since its difficult, if not
impossible, to get a torque wrench on most
driveshaft U-joint hardware, you have to go by
feel. Use the shortest wrench you have that
fits and choke up on the handle. You dont
need a ton of leverage to spin the hardware
in place. It should be more than snug but not
Hulk Hoganed in place or kicked tight with
your size-12 boot.
fourwheeler.com
3. Wrong Luber
Every 4x4 has specific lubrication requirements for each component. If it has a dipstick, you
probably check it at least once a year. If it has an inspection plug, you probably inspect it every
couple of years. But when was the last time you crawled under your 4x4 and hit every grease fitting
with a grease gun? Or better yet, used the proper grease for the correct application? Most experts
agree that any grease is better than no grease at all. However, did you know that CV joints generally
require a moly grease instead of common lithium-based grease? This would include the center joint
of a CV driveshaft and CV-style axleshafts. It can be inconvenient to have two grease guns, but if you
want to do it right, there is only one right way to do it in this case.
4. Beating Drums
Have you ever adjusted the drum brakes
on your 4x4? In theory, you shouldnt have to
adjust them because they are supposed to be
self-adjusting. However, the mechanisms inside
can often become corroded or gummed up with
mud. You do pull the drums off every so often to
hose them out, right? Its also not uncommon for
someone to have reassembled them incorrectly
during a brake job, causing the self-adjusting
feature to not work. Once youve safely raised the
vehicle and made sure your drums are clean and
properly assembled, reinstall the wheels. Adjust
the brakes using a brake spoon. You should feel
only a slight drag as you rotate each wheel.
5. Battery Battering
When our 4x4s dont start on the trail, we know
the battery is fully charged, and we suspect the
battery connections are loose, whats the first
thing we do? If you answered Pick up a rock and
start whacking on the terminals, you get an A
for diagnostics and an F for tool choice. What
you may not know is that an automotive battery
is a somewhat fragile component. Beating on
the terminals can cause the internal lead plates
of a wet-cell battery to become damaged. It can
also cause an acid leak at the terminal itself.
What does that acid do? Well, once outside of
the battery it causes corrosion. Yeah, thats the
nasty white fungus looking stuff on the battery
terminals and cables of your 4x4. That corrosion
in turn causes a poor connection that leads to
you beating on your battery with a rock. Use the
correct tools to work on your battery. This does
not include any hammering device. Clean the
terminals regularly and coat them with a dielectric
grease to prevent corrosion and ensure a good
connection.
6. Overpressure Air
Its estimated that 5 million gallons of fuel
per day are wasted due to low tire pressure.
Were wondering why we dont see these
people off-road. The majority of 4x4s that
we do see hitting the dirt have too much air
pressure in their tires. With higher tire pressures off-road, these drivers sacrifice traction
and comfort. How much you can air down for
better off-road performance depends on the
tires youre using and the weight of your 4x4.
In most cases, a smaller vehicle like a Jeep on
radial tires can run 10-15 psi. With bias-ply
tires, that same Jeep can easily run pressures down into the single digits. Those with
significantly heavier fullsize trucks may need
to experiment with different pressures until a
good bulge in the sidewall is achieved.
fourwheeler.com
TECH 10 THINGS YOURE DOING WRONG
8. Steering Joint
Murderer
7. Suspension Strangler
So you and a few friends spent the weekend installing your new lift kit. You likely gunned all the
suspension hardware in place with the vehicle raised in the air, and now youre wondering why your
4x4 rides like crap. Well, when it comes to most rubber and urethane pivoting suspension bushings
like those found on A-arms, leaf springs, shackles, shocks, and link arms, you shouldnt hit them
with the final torque setting until the 4x4 is sitting on the ground and supporting its own weight. Final
torqueing of the pivot hardware with the suspension fully drooped can cause your 4x4 to ride and
flex poorly. It can also cause the bushings to wear out prematurely.
Aftermarket front axleshaft and U-joint

manufacturers absolutely love a driver that turns
hard into an off-road obstacle or undercut ledge
and stabs the throttle. These companies also love
anyone who engages a front selectable locker
when its not needed, especially when turning on
hard, flat surfaces. One of the most failure-prone
parts on a 4x4 is the front axle steering joint. In
most cases, you should be babying them. Always
keep in mind that the joints are considerably
weaker when the steering is turned. If you have
to attack an obstacle with the throttle, try to line
yourself up so that the steering wheel is straight.
Also, only use the front locker when you need it.
Chirping the front tires and jay-hopping around
nearly paved corners is really hard on many different components. Let the differential do its job.
Considering all of this, its easy to see why a spool
is a terrible idea for a trail 4x4 that needs to steer
around corners.
9. Oil Spiller
10. Ham-fisted Shifter
Its hard to believe that most of us are misusing the typical plastic engine oil container. Its
understandable because engine compartments
nowadays are incredibly cramped. There isnt a
lot of room to maneuver an oil bottle over the oil
filler. Anyway, the container is less likely to glug
and spill oil if you hold the bottle as pictured. The
same is true of antifreeze containers.
Only 15 percent of new car buyers in the U.S. would consider purchasing a manual transmission.
Perhaps even fewer should. Many people cause transmission and transfer case damage and unnecessary wear by manhandling the shifters into gear. You should be easing them into gear. Manual
transfer case shifters are notoriously finicky. Banging on the T-case shifter with all your weight could
damage the shift forks or shift linkage, leaving you stuck. In most cases you can more easily shift a
fussy transfer case if you slowly pull the vehicle forward or back just a bit while lightly leaning on the
shifter. fw
fourwheeler.com
PACKAGE DEALS!!!
CALL FOR PACKAGE PRICE ON ANY TIRE & WHEEL

COMBINATION. INCLUDES COMPUTER SPIN
BALANCING, LUGS, CENTERS & VALVES.
TPMS SENSORS IF NEEDED.
Tech 1-304-233-7917
5 Garden Court Wheeling, WV 26003

Open 8 to 7 Mon-Fri - Sat 9 to 1
NTWonline.com
super swamper
M-16
IROK
TRXUS MT
super swamper
SX
LTB
TRXUS STS
SSR
BOGGER
KM-2
STZ
MXT BY COOPER
Buckshot
Mudder
I & II
MAXXIS
XMT2
TOYO
OPEN COUNTRY
MT
DEEGAN
MTZ-P3
PRO
COMP
TERRA G2 MUD GRAPPLER TRAIL GRAPPLER
COURSER
KO2 NEW
TSL
TRAIL
COUNTRY
FUN
COUNTRY
ATZ-P3
EXTREME
COUNTRY
ATTURO MUD CLAW FEDERAL
AT II
MT
BY COOPER
FEDERAL MT
THOUSANDS OF WHEELS AVAILABLE FROM THESE FINE MANUFACTURERS

Xtreme Alloy
KMC XD
DIAMO
VISION
Dually Wheels In Stock 16, 17, 19.5 & 20
HUGE INVENTORY OF SUSPENSIONS. CALL or CLICK

GM
14-15 GM 1500 . . . . . . . . . . . . .5-$999 . . .7.5 $999
07-13 GM 1500 3 $249 . . . . .5 $999 . . . .7 999
99-06 GM 1500 . . . . . . . . . . . . . .4 $999. . . . ...6 999
88-98 GM 1500 . . . . . . . . . . . .3 $519. . . . 6 999
11-15 GM 2500 HD . . . . . . . . . .5 $1399 . . .7 1399
02-10 GM 2500 HD . . . . . . . . . . . . . . . . . . . . . . .6 1295
01-06 GM 1500 HD & 2500 Non HD . . . . . . . .6 1295
FORD
05-15 S.D. (spacer) 3 $379 . . . . . . . . .(coil) 3 $499

05-15 Super Duty 4.5 $649 . . . . . . . . . . .6 799
05-15 Super Duty 4 Link Adjustable . . . . . . .6 1299
99-04 Super Duty 2 $339 . . . .5 Excursion . . .799
99-04 Super Duty . . . . . . . . . . . .4 . . . . . . . . . . . . .809
99-04 Super Duty . . . . . . . . . . . .6 . . . . . . . . . . . . .879
99-04 Super Duty . . . . . . . . . . . .8 . . . . . . . . . . . .1295
80-98 F250/350 Gas or Diesel .4 . . . . . . . . . . . . .609
2015 F150 (new body) . . . . . . .4, 5 or 6 . . . .1299
2014 F150 . . . . . . . . . . . . . . . . . . .4 or 6 . . . . . . . .999
09-13 F150 . . . . . . . . . . . . . . . . . .4 or 6 . . . . . . . .999
04-08 F150 . . . . . . . . . . . . . . . . . .4 or 6 . . . . . . .1299
80-96 F150 w/arm . . . . . . . . . . .4 $469 . . . . . .6 499
LEVELING KITS (most $99 or less)

04-08 & 09-13...F150 . . . . . . . . .Leveling . . . .2.5 99
05-13 Super Duty . . . . . . . . . . . .Leveling . . . .2.5 99
DODGE
02-05 Dodge 1500 . . . . . . . . . . . . . . . . . . . . .4-51195

06-08 Dodge 1500 . . . . . . . . . . .4 $949 . . 6 999
09-15 Dodge 1500 . . . . . . . . . . .4 $1249 . . 6. 1399
03-13 Dodge Ram HD R.A. drops . . . . . . . . . . . .669
03-13 Dodge Ram HD Adj links. .. . . . . . . . .5 899
94-15 Dodge RAM HD Leveling. . . . . . . . . .2.5 99
14-15 RAM 25/3500 HD . . . . . .. . . . . . . . . . . . . 5 999
JEEP
07-15 Jeep JK w/N20 shocks .2.5 $329 . . . .4 499

07-15 Jeep JK w/N20 shocks .3.5smooth ride499
07-15 Jeep JK w/N20 shocks 6 . . . . . . . . . . . . .999
97-06 Jeep TJ w/N20 shocks 2.5 $2994 . . .4 499
97-06 Jeep TJ X-Series . . . . . .4 $999 . . .6 1049
87-96 Jeep YJ w/N20 shocks .4 . . . . . . . . . . . . .449
97-06 Jeep TJ Long Arm . . . . .4 $1599 . .6 1649
NEW Jeep Long Arm Upgrade XJ $649 . .TJ 899
84-01 Jeep XJ 3 . $255 4.5 $459 . . . . . .6.5 899

84-01 Jeep XJ w/rear springs .4.5 . . . . . . . . . . . .655
TOP QUALITY
93-98 Jeep ZJ Grand Cher . . .3.5 $379 . . .4 599 JEEP BUMPERS,TOPS
FENDER FLARES
93-98 Jeep ZJ ...4 (adj. links) $749 Long Arm 1499 XRC WINCHES GEN II
99-03 Jeep WJ Grand Cher . . . . . . . . . . . . . . 4 499
76-86 Jeep CJ . . . . . . . . . . . . . . .2 $409 . . .4
. 439
Serving Customers for 30 Years!
TOYOTA
05-14 Toyota Tacoma . . . . . . .4 $999 . . .6 $999

07-15 Toyota Tundra . . . . . . . .4.5 $1249 .6 1299
07-13 Toyota FJ Cruiser . . . . .3 $249 . .6 1299
86-96 Toyota Pickup . . . . . . . .4-5 . . . . . . . . . .609
64-80 Toyota FJ-40. . . . . . . . . . . . . . . . . . . . . . . .4 545
71-81 Scout II . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 575
Call or Click For

Latest Prices, Sizes and Specs
NTWonline.com
Wheel Spacers
8 Lug Spacers 1.5, 2, 3 & 4
5 & 6 Lug
1.5, 2 & 2.5
Walk-Ins Welcome 9-5 M-F/9-1 Sat All Tires Plus F.E.T.
TECH LINE 1-304-233-7917FAX 1-304-233-2286TRACK ORDERS 1-800-391-1113
NO returns after 30 daysNO returns on Special orders ItemsAll return subject to 20% Restock fee-Prices Subject To Change
FEATURE
AEV
RAM
I
TEST
DRIVE
F YOURE AT ALL FAMILIAR WITH AMERICAN EXPEDITION VEHICLES (AEV),
you already know what the company can do for the Jeep Wrangler.
Much more than simply a conversion company, AEV engineers suspension systems, exterior upgrades, interior accessories, and wheels
for these popular vehicles. It also offers its complete Hemi Builder Kit
for those looking to perform a V-8 swap. Now the company has waved its
magic wand over the Ram 2500/3500 truck.
The suspension underneath the AEV Ram offers some interesting
mechanical details. Built exclusively for the 2500/3500 Ram truck,
AEVs suspension system features many of the engineering basics that
were incorporated into the companys well-respected JK Wrangler suspension. The concept from its beginning on paper was to make it a dual
sport systemto have excellent road manners, as well as great off-road
terrain handling capability. To do this, AEV worked hard to maintain the
best possible suspension and steering geometry. In addition, it partnered
again, as it had on its JK suspension system design, with Bilstein to create
custom-tuned 5100 series shocks for the AEV Ram suspension.
It would have been easy to make a set of springs for the gas truck and
another for the diesel truck, which is what many aftermarket suspension companies do to create a lift. So why did AEV go a different route?
Because there are dozens of different coil springs for the Ram trucks and
each spring is specifically designed to match the model of truck, depending upon trim level, engine choice, cab style, bed length, wheelbase,
GVWR, and a handful of other specifications. There was no need to reinvent the wheel, so to speak. To design a taller spring to achieve the additional height in an aftermarket suspension system would also mean altering the on- and off-road ride quality and suspension geometry already
built into the Ram truck. Instead, AEV retained the factory springs and
created a system that delivered a 3-inch lift in front and a 2-inch lift in the
rear, while keeping the OE geometry of both the suspension and steering.
The lift was achieved by using specially designed cast-aluminum
lower spring spacers that allowed the suspension geometry to remain unaltered by keeping the coil properly clocked, as well as correctly indexed
horizontally in its factory position. The front coil spacers are eccentricshaped (they look sort of like a horses hoof) to allow the front axle to be
The AEV Ram Power Wagon stands

tall with an AEV 3-inch lift suspension kit and 37-inch BFGoodrich
Mud-Terrain T/A tires. The suspension mods provided improved ground
clearance and off-road capability,
without making the truck so tall that
entry and egress became difficult.
fourwheeler.com
We found the inner off-road animal

inside the AEV Ram
By Stuart Bourdon
fourwheeler.com
editor@fourwheeler.com Photography: Stuart Bourdon
FEATURE AEV RAM TEST DRIVE

moved forward (1-inch on the gas version with
37-inch tires and 1.6-inch on the diesel version
with 40-inch tires) to center the tires in the
wheelwell and correct the radius arm geometry for reduced impact response.
Steering geometry was corrected through
the use of AEVs custom forged drag link,
track bar, and raised track bar tower. This
not only improved steering and handling by
reducing the body roll, bumpsteer, and roll
steer commonly associated with lift kits, but it
brought the roll center height of the frontend
back to better than factory. Out back, AEV
custom bumpstop spacers, a rear track bar
relocation bracket, sway bar end links, and a
new power hop bracket (if applicable) get the
rear suspension back into proper shape.
If youre wondering how AEV fit 37-inch
tires on a Ram truck with only 3 inches of lift
underneath it, well, some very smart fender
trimming and a set of proprietary flares provide just enough room for up travel without
leaving a gaping hole when the truck is at rest.
The Ram we drove that day was decked out
in a set of AEV Salta HD wheels, inspired by
those seen on international off-road race rigs.
You can also get the AEV Ram with the companys Katla wheels. Both are A356/T6 cast
aluminum with valve stem recesses.
The nose of the AEV Ram was well protected by its modular Front Bumper System.
Based on a 316-inch stamped steel superstructure, the bumper was outfitted with a top tube
that accommodated a 20-inch LED lightbar,
heavy-duty tow loops that were anchored to
the frame horns, and side wings that offered
multiple light options. The massive bulwark
supports up to a 16,500-pound winch (AEV
offers Warn products).
One of the most obvious enhancements was
the AEV Raised Air Intake. Snaking from
out of the passenger side of the front cowl, the
snorkel-like UV-stable cross-linked polyethylene structure offered more than just deepwater fording capabilities. Its designed to stay
above the dust of the rig in front of the AEV
Ram and away from the heat of the engine
to deliver the coolest and cleanest air charge
possible. To make it even better, our tester had
the optional High Efficiency Dust Filtration
System on top, making it look like a giant
mushroom of particle trapping efficiency.
So how did it drive? Lets start with the

fact that the AEV rig we drove was based on
Rams recently reintroduced Power Wagon
platform. Right off the bat, it possessed offroad super powers such as electronic locking front and rear differentials, making the
4.10-geared axles a force to be reckoned with,
especially when given a few more inches of
ground clearance and shod with a tall set of
aggressive BFGoodrich Mud-Terrain T/As.
We accomplished climbing even the
steepest inclines we could find at Southern
Californias Rowher Flats ORV area without
trouble or spinning the tires by locking it
down into 4-Lo, with front and rear lockers
active and feeding the brawny 6.4L V-8 Hemi
just enough fuel to keep it chugging along
but not enough to make the tires do anything
but bite into the landscape. Descent was only
slightly less fun (we prefer climbing), but low
gearing and the trucks Hill Descent feature
allowed us to simply point the truck down
the mountain and let it do all the work, while
trying to stay off the brakes unless absolutely
necessary. On-road manners were, well, trucklike. Lets face it, this is a 34-ton pickup, but its
5
1. The modular AEV Front Bumper System on the
Ram is of Herculean proportions and strength. It
can be orderead with a number of accessories,
including an LED lightbar, winch, and fog lights.
2. The tow loops that are integrated into the AEV
Front Bumper System are massive and allow for
attachment of winch hooks or D-rings. AEV told
us they are line-pull rated at 30,000 pounds and
secured to the framehorns.
3. A winch can be imbedded in the AEV Front Bumper System, which can accept up to a 16,500-pound
capacity unit. AEV offers Warn products, but some
other winches may fit in the bumper.
4. Underneath the tube bar on the AEV Front Bumper System, we found a 20-inch LED lightbar, an
available option when you order the AEV Ram.
2
5. A roller fairlead was mounted to the face of the

AEV Front Bumper System. This setup comes as a
package with the optional Warn winch.
fourwheeler.com
ride quality (most likely due to the well-tuned

coil spring suspension system) was posh for a
nearly 3-ton beast, and handling was on par
with or better than other pickups its size we
have navigated through suburbia.
All in all, we want more. One day was
definitely not enough, and before it was over,
we were asking how to get our hands on it for
a full weeks test drive. Youll know right after
we do if that happens. In the meantime, were
satisfied knowing that AEV has improved
on the Ram Power Wagon, a vehicle that was
already a quite capable off-roader.
10
6
6. The drop bracket for

the front link arms lowers
and moves forward the
front axle. This helps
with tire clearance and
suspension geometry.
The bracket allowed AEV
to retain the factory link
arms on the Ram Power
Wagon.
11
7. Each factory link arm gets a small skidplate/

deflector to keep rock or other obstacles that the
truck may be sliding over to come into contact with
or damage the AEV bracket. You can also see the
aluminum driveshaft spacer between the flanges of
the front driveshafts CV joint that compensates for
the forward placement of the front axle.
8. As much as we liked the AEV Ram, if it were
ours, we would probably add a skidplate up front to
protect the steering box and the auto-disconnect
system for the front antisway bar.
9. AEV retained the factory coil springs because

each model of Ram truck, depending upon trim
level, engine, cab style, bed length, weight, payload, and any number of other specifications, gets
its own specifically tuned coils. AEV saw no reason
to reinvent the wheel. The lower spring spacer that
is part of the lift system is shaped to allow for the
forward shift of the front axle, while maintaining
the clocking and vertical alignment of the coil.
10. AEV prefers its Raised Air Intake system not be
called a snorkel. It wants you to understand that it
not only delivers deep-water fording capabilities but
also sources cooler and cleaner air by being outside
of the engine cowl and above the dust created by
the rig in front of it.
11. Just in case its not obvious to the onlooker that
this an AEV-converted Ram, the front grille proudly
wears an AEV badge in place of the Ram-head
emblem from the factory. fw
SOURCE
8
fourwheeler.com
American Expedition Vehicles
248/926-0256, aev-conversions.com
FEATURE
BACKWARD GLANCES
Multitool: The 1947 Dodge

WDX Power Wagon That Does
Everything
HE STORY OF THE POST-WORLD WAR II
Dodge Power Wagon closely parallels

that of its brother in arms, the WillysOverland Jeep. Both companies built a
wartime vehicle that earned legendary status
in the war, and both followed up with a civilian counterpart that built on that reputation
and became legendary out of uniform as well.
The WWII Dodge VC and WC series
trucks were ever present, and Dodge dominated the wartime production of 12- and 34ton trucks from 1940 to 1945. Heck, they
dominated light tactical truck production well
into the 60s. Their trucks were the just-right
combination of adaptability, beef, capability,
and cost that makes for a legendary military
truck. Those characteristics have kept them
competitive in the light-truck market since
then as well.
As with Willys-Overland, Dodge began
Well, the paint isnt perfect, but this nearly

70-year-old truck is still virile, vigorous, and potent
and isnt afraid to go toe to toe with any other truck.
The Dark Green paint is still original and somewhat distressed, but Clint had to repaint the
black on the fenders to preserve the metal.
A base 7,600-pound GVW truck cost $1,764
new and didnt come with a heater or rear shocks.
The MU-2 Winch from Braden was rated at a modest 7,500 pounds but carries 150 feet of 38-inch
cable. It was essentially the same winch offered
for the military rigs of WWII.
Not many newer
pickups can hitch up
to a plow or a posthole digger, or run
a belt-driven farm
implement. Dixon
installed a Monroe
hydraulic lift on the
truck, which is also a
period piece. In this
era, Power Wagons
were built at Dodges
Warren, Michigan,
truck plant or at a
Los Angeles facility.
By 1950, West Coast
production moved
north to the Bay
area in San Leandro,
California, and were
built there through
most of 1954. Annual
production of Power
Wagons out west was
typically very low.
fourwheeler.com
BY JIM ALLEN EDITOR@FOURWHEELER.COM PHOTOGRAPHY: JIM ALLEN COLLECTION
making plans for a postwar version of the

WC series trucks before the war actually
ended. As it was nearing introduction, the
automotive rumor mill had it called the
WDX General Purpose Truck, and there
were even some preliminary materials handed out using this name. By the time sales
began in March 1946, the Power Wagon
name had been applied. This also happened
to be the name of one of the earliest automotive trade magazines and the name of a truck
company started by Max Grabowski. The
Grabowski Power Wagon Company of Detroit was in business from 1908 to 1913, but
its truck had no relation to the Dodge. Time
soon obscured Max and the trade magazine,
but the Dodge Power Wagon has lived on.
The Dodge model T-137 WDX Power
Wagon was loosely based on the T-214
Dodge military trucks commonly known
as the WC Series. The 34-ton WC models
were introduced in 1942 and replaced a
line of 12-ton 4x4s. They came in a variety
of wheelbase lengths, including 98, 114,
and 121 inches. For the WDX, a 126-inch
wheelbase was chosen so a good-sized cargo box could be added. A prewar 1940-style
cab was used along with a hood and front
end inspired by the Burma Road 3-ton
Dodges built for the Chinese government in
1945. The fenders were roughly the same as
the military Dodges, and a new four-stake
pocket, 8-foot pickup bed was developed,
though other types of rear bodies were
optional. The truck definitely had a civilian
appearance but with a strong reminder of
the military roots. Five colors were avail-
able: Dark Green, Red, Dark Blue, Yellow,

and Seawolf Submarine green.
Mechanically, the T-214s 230ci L-head
six translated from the military truck, as did
the New Process four-speed transmission.
Where the T-214 Weapons Carrier had a
single-speed transfer case, the WDX used a
two-speed divorced unit very similar to the
New Process unit designed for the WWII
Dodge 112-ton 6x6. This transfer case was,
in fact, the direct ancestor of the NP205.
The axles were largely the same as those
used for the 6x6 or the Weapons Carrier
and they were very stout dropout units with
9.63-inch ring gears, four pinion differen-
tial, and 1.375-inch chrome alloy shafts.

The front axle steering knuckle used the
almost-forgotten Tracta-Joint. An interesting tidbit is that the ancestor of the Detroit
Locker was designed to fit this application
in WWII. The military was looking for
enhanced mobility on the Dodge 6x6 trucks
and had some fit with the Thornton No-Spin
differential, which had been introduced in
1941. The No-Spin was originally designed
as an interaxle clutch on the Thornton Tandem Drive of the 30s.
The WDX came in two weight classes,
the standard 7,600-pound GVW and the
8,700-pound version. The difference was
The WDX engine was nearly identical to the wartime 230ci flathead and was rated for the same
power and torque. Net power was about 80 hp,
but Dodge advertised the gross 94hp rating. The
King-Seeley governor is visible on this side (belt
removed to save wear and tear) and on the other
side mounts the belt-driven Hy-Lo hydraulic pump
that runs the Monroe lift. For stationary work, a
partial fan shroud and overflow tank ensured the
engine stayed cool.
Have auger, will travel at a top speed of 55 mph. This 50s-vintage Roper auger can drill 8, 10, 14, 18
or 24-inch-wide holes at 3 feet deep. The unit mounts to the Monroe three-point hitch and is driven off
the rear PTO, which can be used with a splined shaft or a beltdrive drum. Any number of PTO-driven
tools and implements were available from Dodge or aftermarket.
fourwheeler.com
mostly tires and gearing. The 8,700-pound

truck had higher-rated 9.00-16s with 5.83:1
axle ratios, while the lighter truck had 7.5016s with 4.89:1 ratios. The 7,600-pound
unit had 8-leaf front spring and 12-leaf rear
spring, while the higher-rated truck got 11leaf and 14-leaf spring packs. Both trucks
were nominally 1-tons.
The WDX designation deserves a few
words. The W, which came from the same
naming convention as the WC series military
trucks, indicated a 41-47 model year truck.
The DX indicated the new civilian 1-ton
4x4 truck. This naming convention would
change for 48 vehicles, but both the 46 and
47 Power Wagons would remain WDX. The
T-137 designation was Dodges model desigFOUR WHEELER FEBRUARY 2016 53
FEATURE 1947 DODGE WDX POWER WAGON
The original four-pocket bed

was used through the 50 models, and being large and deep, it
could carry 60 cubic feet of material. The 10-ply 9.00-16s offered a lot of overkill on the load
ratings and was the same tires
used on the military rigs. These
tires were about 35 inches tall
and so stiff that, with an empty
truck, air is almost optional.
Back in the days where men
were men and women were glad
of it, truck interiors were nothing fancy. And this is the Deluxe
cab! They did have a little sound
deadening on the firewall.
nation for the Power Wagon, but it was used

internally for the most part.
The WDX had few people-pleasing options, though many for functionality. Among
the people-pleasers was a heater, which was
commonly optional in trucks back then. The
Deluxe Cab came with vent-wing windows,
driver armrest, dual visors, dual wipers, a
dome light, and a headliner. Functionally, a
bunch of stuff was on the options list, which
would grow to gigantic proportions eventually. For 46 vehicles, the 7,500-pound Braeden
MU-2 PTO winch would head the list. Front
towhooks and a rear draw bar would be the
40s definition of connectivity. A PTO driven
off the transmission supplied

power to the front winch or a
rear pulley drive, or both. A
governor made PTO operation consistent.
In 1950, the University
of NebraskaLincoln would
test the T-137 Power Wagon
as a tractor. The University
of Nebraska had been performing tractor certification since the early
part of the 20th century, first just to verify
manufacturers claims for Nebraska farmers
but later for the entire country and even the
world. Since Dodge was marketing the Power Wagon as a do all vehicle and a threepoint rear hitch was available, a 50 model
was sent for tests usually reserved for farm
tractors. It was given an official PTO belt
power rating of 43.26 hp at 1,700 rpm and a
drawbar horsepower rating of 40.52 hp. At
the maximum PTO rating, the truck used 4.9
gallons of fuel per hour. Maximum drawbar
pull was rated at 6,480 pounds with 12.82
percent wheel slip. This test had the truck
weighed down with 1,188 pounds of castiron weight added to the front wheels and
2,114 pounds added to the rear, for a total of
a 9,110 pounds truck weight. At the trucks
standard 5,809-pound working weight (with
the three-point hitch and other items), the
truck generated 3,300 pounds of drawbar
pull at a bit more than 7 percent wheel slip.
At its rated drawbar load, the truck used 4.3
gallons of fuel per hour in 10 hours of use.
The 47 WDX Power Wagon you see belongs to Clint Dixon, a very notable expert
on the Power Wagon, and its a time capsule.
Its an 8,700-pound GVW model he acquired
in 1980 from the original owner. It had been
used to erect windmills in South Dakota
up to that time. Its been spruced up and
mechanically overhauled but is essentially
original cosmetically. Dixon added a number
of period accessories for his own fun, and he
still occasionally uses the truck in his carpentry business. fw
THE DETAILS
Vehicle: 47 Dodge WDX Power Wagon
Owner: Clint Dixon
Estimated value: $30,000
Engine: 230ci Dodge L-head
Power (hp): 94 @ 3,200 (gross)
Torque (lb-ft): 185 @ 1,200
Bore & stroke (in): 3.25 x 4.63
Comp. ratio: 6.7:1
Transmission: 4-spd, New Process (non-synchro,
Spur-Gear)
Transfer case: 2-spd, New Process
Front axle: 9.63in Dodge
Rear axle: 9.63in Dodge
Axle ratio: 5.83:1
Tires: 9.00-16
Wheelbase (in): 126
GVW (lbs): 8,700
Curb weight (lb): 5,247 (incl. winch)
Fuel capacity (gal): 18
Min. grd. clearance (in): 10.38
Approach angle (deg): 40 (w/winch)
Departure angle (deg): 28
fourwheeler.com
WARN VR
PACKED WITH SOMETHING
RARE IN ENTRY LEVEL WINCHES:
DEPENDABILITY
Available with
steel or Spydura
synthetic rope.
Choose from
8-, 10- and
12,000 pound
capacities
WARN ENGINEERED. TESTED TO THE EXTREME.

The WARN VR may be an affordable entry-level winch, but its
built to help you make a quick exit from tough situations. Bolt
one to your bumper now, and its yours for the long run. After
all, its backed by the most trusted name in off-roading: WARN.
Get one today at your WARN Authorized Dealer,

or learn more at warn.com
G O P R E PA R E D
TECH
CUMMINS
COLD SHOULDER
Five ways to combat Cummins cold-start problems
By Cody Kanuscak
editor@fourwheeler.com Photography: Cody Kanuscak
HEN THE TEMPERATURE DIPS TO THE
bottom of the needle, diesel fuel

transforms into a consistency
resembling molasses, leaving the
wax particles within the fuel and thickening
or gelling inside the arteries of the truck
clogging. And just like cholesterol clogs human arteries, gelled diesel fuel in your trucks
fuel system is like a heart attack waiting to
happen. Most diesel fuels can withstand 32
degrees. For most of us, we know it often gets
much colder than that! Here are five easy ways
weve found to help defend your Cummins
against the evil freezing arctic temperatures.
Fuel Additive: This simple solution should always be running in the veins of your 4x4 at all times during
cold months. As an added bonus, it contains cleaners to help remove deposits that are built up within
your fuel system, as well as additives to combat the gelling process in colder temperatures. In short, it
prevents the paraffin wax found in diesel fuel from thickening. Diesel fuel additives usually have a cetane
booster that helps with faster start up times. Cetane is the measurement of delayed ignition of the diesel
fuel represented by a number. Most U.S. filling stations have diesel fuel with a cetane rate of 45. Increasing
cetane levels in your diesel fuel will help with faster ignition times for your diesel engine.
1.
Batteries: Long starts drain the batteries in colder conditions. Youll find two batteries in parallel
maximize the cranking amps (CA) needed to spin your diesel engine and ignite the air/fuel mixture.
When purchasing your next battery, look for a rating of cold cranking amps (CCA). This measurement is
found on the battery and is a measurement based on 30 seconds of starting while holding at least 7.2 V.
The minimum need for most diesel engines is around 750 CCA.
2.
3.
Engine Preheater: Your Cummins engine doesnt come with glow plugs. Its equipped with a grid
heater that uses electrical current in a heating element that is shaped like a grid. This maximizes
fourwheeler.com
surface area warming the air to be drawn through the engine block for ignition. As soon as the key is turned to the On position, the heater then will heat
the grid. Once it reaches the set temperature, your dash light will turn off
letting you know its time to turn your key over to the Start position.
Coolant: Sometimes when a low coolant warning shows up, some of
us just add water thats nearby for a simple solution. This isnt always
a bad thing since most antifreeze mixes are 50/50 coolant and water mix.
Unfortunately, water will start to crystallize to ice when the temperature falls
to 32 degrees. This can lead to cracked blocks, lines, and radiators. On the
other end, most antifreeze manufactures recommend not going more than
70 percent coolant mix to help keep the heat transfer and other benefits, like
freeze/boilover ratings, optimal. So before the freezing season starts, its a
good time to perform a coolant flush so you have the right mix going into the
cold season.
4.
Oil: This fluid doesnt seem like it plays a role in the help of starting your
diesel, but in reality, it does have a dramatic effect since so many rotating engine parts are submersed in it. The term viscosity is the measurement
of fluid while drawing the fluid through a device known as a viscometer. Its
then labeled with the correct weight rating. For example, with 10W-40, the
first number is the viscosity of the oil when the oil is cold. The W means it
has been tested at colder temperatures, or winter rated. In this case, the 40
is known as the thickness when the oil becomes warm. The thicker the oil in
colder environments, the harder the oil is to flow, leaving more resistance on
internal parts on the engine and creating more drag, especially when starting.
5.
4
1. Adding Royal Purple Max-Tane fuel additive to your Rams fuel tank will give a
cetane boost of 8. We mix 1 ounce of Max-Tane to every 2 gallons of diesel fuel
for max performance.
2. On the far right of the Optima battery label youll find the battery ratings.
CA stands for cranking amps and CCA is the cold cranking amps rating. A
minimum of 750 CCA is recommended for diesel applications.
3. The grid heater can malfunction or the elements get coated in soot, reducing
their effectiveness. If it needs replacement or cleaning, you can get to the Cummins grid heater by removing the four bolts on the intake and the oil dipstick.
Behind the intake there is one somewhat-hidden bolt on the intake that will
need to be removed to take your intake off.
2
fourwheeler.com
4. Two bolts that have the electrical source to the grid heater will need to be
loosened for the last step of the removal process.
TECH CUMMINS COLD SHOULDER
5
5. When finished with removing the intake grid
heater, its a good idea to stick a vacuum hose
down the intake to remove any loose debris that
may have fallen in before installing the new part.
6. After placing the grid heater gasket on, you can
put two bolts in the grid heater to help it stay in
place to tighten the two electrical connections on
the rear of the grid heater. Then remove the bolts to
lay the second gasket between the grid heater and
intake. Tighten remaining bolts and youre finished.
7. After draining the entire radiator from the lower
8
petcock, we added a bottle of Royal Flush then

topped it off with water to let it run for 15 minutes
with the heater on High to circulate all coolant
lines. After the engine is cooled down, drain the
system and then repeat topping off with water to
let it run another 15 minutes. Once the engine is
cool, drain the radiator and youll see containments
flowing out of your system.
9. Royal Purple 10W-40 is our choice for our Cummins engine this winter. In warmer weather well
swap out to 15W-40. Remember, almost 3 gallons
of oil is needed after the filter change to fill your
Cummins back up. FW
8. With the proper ratio of coolant and water

established, we then topped off our coolant system
with a bottle of Royal Ice coolant additive to help
condition the radiator.
SOURCES
Optima Batteries
888/867-8462, optimabatteries.com
Royal Purple
888/382-6300, royalpurple.com
9
fourwheeler.com
FEATURE
Not your average shop truck
FLATBED E-3
fourwheeler.com
Despite its size and storage capacity,

the bed is relatively light. This mean
s Steuber has plenty of cargo carrying capac
ity. To help increase the off-road prowe
ss of
the E-series, 18 inches was removed
from the rear. Ujoint took full advan
tage of
this when building the custom bed.
The extreme slant and flush-mounted
lights
provide plenty of departure angle,
and despite its rather long wheelbase
, it works
surprisingly well on the trail.
By Ali Mansour
50
fourwheeler.com
editor@fourwheeler.com Photography: Ali Mansour
HEN YOUR BUSINESS IS BUILDING 4X4 VANS, YOU DONT HAVE TO TRY TOO HARD FOR YOUR WORK TO STAND OUT IN
a crowd. Specializing in 4x4 conversions for 92-newer Ford E-Series vans, Ujoint Off-Road owner
Chris Steuber is an expert in practically all things E-Series. Looking to build a new shop truck/wheeler, Steuber decided to think way outside of the box with what he simply calls V4.
Since Steuber routinely hauls parts and build materials for his shop projects, he wanted a versatile rig that
could double as a shop truck. Given his enthusiasm for wheeling and camping, he also wanted something that
could handle harsh off-road conditions while toting his custom bed-mounted camper. The result is the custom
flatbed van you see before you.
Starting with a 7.3L diesel-powered 02 E-350, Steuber and his crew wasted little time modifying the original
van body and frame. While the cab closeout was done using a fiberglass conversion kit from Blackhawk Industries, the aluminum bed was crafted entirely in house at Ujoint. Weve had a chance to see the rig in action more
than once and are still surprised at some of the places he manages to push the long-wheelbase machine.
With its unique proportions, its definitely not quite a truck but not really a van in a conventional sense either.
Whatever it is, it flat works great.
FEATURE FLATBED E-350

1. Originally a two-wheel-drive, the E-350 was fit
with an Ujoint Off-Road solid-axle conversion kit.
The 6-inch-lift leaf springs do a great job supporting the nose-heavy 7.3L diesel and isolating the
high-pinion Dana 60 front axle. A crossover steering
system and an RSC upgrade from Ujoint helps the
van steer easy, while maintaining compatibility with
Fords stability control system. Brakes came from a
Ford F-550.
2. One of the most unique features of the allaluminum bed is how its attached to the E-350
frame. Instead of having a rigid bed mount, a threelink bed support system was created. This allows
the bed and frame to pivot independently from one
another. This is especially helpful given the length
of the rig and the twisting that it sees off-road. A
30-gallon auxiliary fuel tank was also built into the
bed to offer more range.
3. To complete the four-wheel-drive conversion, a
NV271 chain-driven transfer case was bolted to the
back of a 4R100 transmission. This is the same
type of aluminum case found in most 34 and 1-ton
late-model trucks. Custom heavy-duty drivelines fit
with 1350 double-cardan joints were installed front
and rear to get power to the full-float axles.
4. While the 37s and a 6-inch lift give the van

ample ground clearance, the addition of the Ujoint
Off-Road front bumper increases the approach
angle and protection. The aluminum front bumper
holds a 16.5 Warn winch that was paired with a
synthetic winch rope from Southeast Overland. The
Rigid Industries 30-inch LED lightbar gets plenty of
use on late-night trail exploration.
5. A major part of the vans look and features was
accomplished by using a Blackhawk Industries cab
closeout. Were told that the fiberglass shell required plenty of work to get just right, but the final
product looks great. Since the van also travels far
beyond your standard trailhead, two fullsize spare
tires were adorned on the back of the cab. Finishing
out the bed is a Rhino Liner coating.
AT A GLANCE
GENERAL
Vehicle: 02 Ford E-350

Owner: Chris Steuber
Stomping grounds: Fletcher, North Carolina
Build Time: 1 year
DRIVETRAIN
Engine: 7.3L Power Stroke turbodiesel
Transmission: 4R100
Transfer case(s): NV271
Low range ratio(s): 2.72:1
Crawl ratio(s): 33.61:1
Front axle/differential: High-pinion Dana 60/Ujoint
Off-Road Stage 2 w/RSC upgrade, Knoll Racing Power
Lock, 4.56 gears
Rear axle/differential: Sterling 10.5/ARB Air Locker,
4.56 gears
SUSPENSION
Front: Ujoint Off-Road 6-in leaf-spring conversion,
Ujoint dual-shock mount w/Bilstein 5160 shocks
Rear: Ujoint Off-Road custom leaf springs w/Ujoint
overload air bags, Bilstein 5160 shocks
Steering: Ujoint crossover
TIRES/WHEELS
Tires: 37x12.50R17 Mickey Thompson MTZ Radial
Wheels: 17x9 Mickey Thompson Classic Lock
MISCELLANEOUS
5
Armor: Ujoint Off-Road front bumper, custom aluminum bed, Dynatrac diff covers
Cool stuff: Ujoint Off-Road onboard air; Diamond Eye
turbo-back 4-in exhaust, DP Custom tuner, Mag-Hytec
trans pan, 30-gal aux. fuel tank, Rigid 30-in lightbar,
Auto Meter gauges, Warn 16.5 winch, Southeast Overland synthetic winch rope, Spod controller fw
fourwheeler.com
10 TRUCKS ENTER, 1 TRUCK WINS

HARDCORE OFF-ROAD DVD!
Directors cut feature-length

double-DVD collectors set
155-minute running time
Exclusive in-depth coverage of
competitors, action, and trucks
ORDER THE DVD TODAY!
800/213-5668
WWW.4WHEELPARTS.COM/TTC
HOLLISTER HILLS SVRA, CA
TECH
SPOTTERS GUIDE
Bronco II Bio: A Ford SUV
By Jay Kopycinski
editor@fourwheeler.com Photography: Jay Kopycinski & Ford Motor Company
HE CLASSIC FIRST-GENERATION BRONCO AND THE FULLSIZE BRONCO HAD
both been highly popular 4WDs when Ford decided to introduce

a scaled-down version of its bobtail SUV. The Bronco II was
introduced for the 84 model year after GM made a move into
the smaller-SUV market segment about a year earlier with its S-Series
1st Generation
(1984-1988)
The Bronco II shared many of the traits of
the fullsize Bronco of the day. Ford used the
Twin-Traction Beam (TTB) style of independent front suspension. Coil springs were used
up front and leaf-spring packs in the rear. All
Bronco II models were four-wheel drive initially, with a two-wheel-drive version offered
from 86 models onward.
Blazer and Jimmy models. The baby Bronco shared a similar design
to the Ford Ranger truck of the same era. The short wheelbase spanned
94 inches from axle to axle, putting it in the same ballpark as the Jeep
CJ-7. Unfortunately, the Bronco II would survive production for only
seven years before the Explorer would push it out of the Ford lineup
In the beginning, Ford used the Germanbuilt Cologne 2.8L V-6 engine. It used a
feedback-type emissions-compliant carburetor. The engine was improved a bit for 86 vehicles. It was bumped to a 2.9L displacement
and outfitted with multiport electronic fuelinjection governed by the Ford-designed EECIV engine control computer. There was also
the option of a 2.3L Mitsubishi turbodiesel I-4
engine during the first three production years.
It proved to be a weak powerplant option.
Only the 84 model was offered with a

four-speed manual transmission, the Toyo
Koygo TK4. In subsequent years, several fivespeed manuals were used, including the Toyo
Koygo TK5, Mitsubishi FM145, and Mazda
M5OD. For an automatic, it was the Ford C5
three-speed the first two years or the A4LD
(0.75:1 overdrive) four-speed starting in the
85 models.
The first-generation Bronco IIs all used the
aluminum-case, chain-drive BorgWarner 1350
fourwheeler.com
When introduced as a 84 model, the Bronco II was

much like the F-150 and standard Bronco, just scaled
down. It was built on a ladder frame similar to the Ranger
pickup. Power steering was standard, and the brakes
were power-assisted disc/drum units. Rear-wheel antilock brakes were offered starting with the 87s.
transfer case (2.48:1 low range). The initial versions were all mechanical-shift cases, but an
electric shift-on-the-fly version was added as an
option starting with the 86 models.
Axle ratios offered were 3.45:1, 3.73:1, or
4.10:1. Front axles were reverse-cut gear Dana
28s using 23-spline axleshafts. Some of the lateproduction 90-model Bronco IIs got the larger
Dana 35 (27-spline) front axle. Rear axles in
all Bronco IIs were the 28-spline Ford 712-inch
unit. Some Bronco IIs came with an optional
limited-slip differential in the rear axle.
Fords Twin-Traction Beam (TTB) independent front

suspension was introduced on the 80 model F-150 and
fullsize Bronco. The same system was scaled down and
used on the Bronco II.
Manual locking hubs
were standard, with auto
locking hubs optional.
Some models used the
electric-shift Touch Drive
transfer case.
2nd Generation
(1989-1990)
The Bronco II was restyled for the 89
model year with a revised front end and some
The early carbureted Cologne engines worked fairly well when new, but as the
feedback-controlled carburetor system aged, it would often start to malfunction
and operate poorly. Some owners have swapped Ford fuel injection onto the
engines. Others have looked to engine swaps. Common swaps are 4.0L V-6 engines from an Explorer or newer Ranger truck, or a Ford 5.0L V-8.
The Bronco II was compact and narrow as compared to its bigger brother. It
was about 10 inches shorter.
fourwheeler.com
TECH SPOTTERS GUIDE, BRONCO II

Early fullsize Broncos had a removable
top; however, this was never a feature on
the Bronco II. The rear side glass wrapped
up onto the roof area and factory sunroofs
were optional with some trim packages.
interior changes as well. The body grew

slightly in overall length from 158.3 inches
to 161.9 inches, but the wheelbase remained
the same.
The suspension and drivetrain remained
mostly unchanged. The Cologne 2.9L V-6
continued to be the lone engine offering
along with the Mitsubishi or
Mazda five-speeds and the
A4LD automatic transmission.
BorgWarner (BW) 1350 transfer cases were used for the 89 models,
but the 90 models electric versions
swapped to the BW1354 transfer case with
the same 2.48:1 low-range ratio.
All Bronco IIs came from the factory with a Ford 712-inch rear axle.
A common upgrade is to swap in an
8.8-inch axle from a Ford Explorer.
This increases spline count from 28
to 31. This swap can also get you
rear disc brakes.
Most 4WD Bronco IIs used a BW 1350 transfer case

(shown here). Many of the 2WD Bronco IIs also used a
4WD version transmission and a similar transfer case, but
the front of the transfer case was capped and its output
not used. In this case, its possible to convert a 2WD
model to a 4WD model using factory parts, while keeping
your original transmission.
Ford would do a partial redesign on the Bronco II for the 89 model year,
updating the front end. However, this generation would survive a scant two
years. The Bronco II would meet its demise about the time Ford introduced
the 91 Explorer.
The German-built Cologne engines sometimes suffered from overheating issues that could lead to cylinder head cracks. Coolant could leak from
passages into the engine oil, contaminating it and causing further internal
engine damage. fw
fourwheeler.com
INTRODUCING
AN ALL-NEW
MOTORTREND.COM
FASTER. SLICKER. MOBILE OPTIMIZED.
EVERY CAR, TRUCK, AND SUV EXTENSIVELY REVIEWED IN OUR ALL-NEW
BUYERS GUIDE. ALL THE AUTOMOTIVE NEWS YOU NEED TO SEE, THE SECOND IT BREAKS.
EXPERIENCE A NEW-AND-IMPROVED MOTORTREND.COM. ITS THE DESTINATION FOR
ALL YOUR AUTOMOTIVE NEEDS. SEE IT FOR YOURSELF AT MOTORTREND.COM.
TECHLINE
TDS OR BUST?
How is the Tierra Del Sol Desert Safari

event held the first weekend in March
every year? It looks like sand dune kind of terrain. Is there a lot of crawling?
DANIEL CHAVEZ
VIA FACEBOOK.COM/JOHNCAPPA4X4
The Tierra Del Sol (TDS) Desert Safari offers lots of cool technical terrain that can
be challenging for all levels of four wheelers.
There are some high-speed sections, some
areas that require crawling, and some really
silty and sometimes muddy areas. While there
are some rocks, most of them are jumbled and
as large as bowing balls. The most fun (at least
for us) is generally found in the water-carved
notches. Much of the terrain is made up of
sandy, silty, dried mud hills. Every winter,
the rains can change the trails significantly.
Seasonal erosion can make what was once an
easily passable trail, an extremely challenging
one. The other plus is that much of the sandy
silt simply crumbles when body metal come in
contact with it. Its not even as close to abusive
as Johnson Valley granite or Moab sandstone.
Of course, your paint will get marred, but a
good solid pair of rocker guards and some
stout front and rear bumpers is usually all you
need to keep the body from getting banged up.
Almost any 4x4 can be fun at the TDS event.
At least one traction-adding device (preferably in the rear) is more than enough to have
COMPILED BY JOHN CAPPA EDITOR@FOURWHEELER.COM
a blast at the TDS Desert Safari. For more

information about the event and host club,
go to tds4x4.com.
ORANGESTUFF OR
YELLOWSTUFF
What is the difference between EBC Orangestuff SUV pads and the Yellowstuff
pads? Which should I be using?
CHUCK JANISCH
EBC Brakes (ebcbrakes.com) offers

performance brake pads for many different street and track applications. There has
been a bit of confusion recently, though. EBC
has offered the Orangestuff full-race pads for
several years. These pads are not suitable for
street use and were developed for the track.
They need to get very hot before they really
start working properly. The confusion stems
from the recent introduction of the orangecolored EBC Extra Duty Light Truck, Jeep, and
SUV brake pads. Like the Orangestuff pads,
these pads feature an orange backing, but they
are not called Orangestuff pads. It used to be
that EBC recommended the Yellowstuff pads
for truck, SUV, 4x4, and Jeep applications.
Today, the company is promoting the new
Extra Duty Light Truck, Jeep and SUV brake
pads for those applications. If I had to guess,
I suspect EBC will eventually phase out the
Yellowstuff pads for the truck, SUV, 4x4, and
Jeep applications.
PERMANENTLY LOCKED
MANUAL HUBS
I recently removed, cleaned, and

greased my manual locking hubs. I
reassembled them correctly and put them
back on the 4x4. For some reason they will no
longer unlock unless I remove the locking cap
and jiggle it. What happened to my hubs and
why dont they work properly anymore?
ERIC MCGREW
VIA EMAIL
Its a good idea to periodically check and

clean the manual locking hubs on your
4x4. If your 4x4 is equipped with serviceable
wheel bearings, you might as well repack them
at the same time. Inspect the locking hubs
closely. Look for grit and evidence of water
intrusion. Manual locking hub companies such
as Warn (warn.com) offer hub service kits that
WHERE TO WRITE
ave a 4x4 tech question you want answered in Techline, drop an email to editor@fourwheeler.com
or head on over to our forums at fourwheeler.com. All letters become the property of Four Wheeler,
and we reserve the right to edit them for length, accuracy, and clarity. Due to the volume of mail, electronic
and otherwise, we cannot respond to every reader, but we do read everything.
include new seals, gaskets, clips, and other

miscellaneous locking hub hardware.
The biggest mistake we see people make
is adding too much grease to the hub mechanism. It should not be packed with grease. The
excessive grease causes a suction so the locking ring does not disengage. The locking hub
mechanism should only be lubricated with a
very light film of grease or spray lubricant. This
is done mostly to prevent corrosion.
In your case, youll need to disassemble the
hubs and wipe out the excess grease. Once you
clean the hubs out and reassemble them, they
should work like new again.
LONGER OR NOT?
Do you recommend installing a stretch

kit on two-door JK that increases the
wheelbase to 105 inches? Im worried about
how complicated the installation is and how it
will affect the handling.
SALIM FAKHOURI
Thats a tough decision. It really depends

on how you plan to use the Jeep and
if you like the way a stretched Jeep looks. If
steep climbs and ledges are your thing, then
the longer wheelbase will make your Jeep more
capable and stable. If technical rocky riverbeds
are your wheeling of choice, you may prefer the
shorter, more nimble wheelbase. The handling
of the Jeep after installation will depend on
the geometry of the suspension, not so much
the wheelbase itself. Im not sure which kit you
are using as there are several out there. Most
of them require welding and some fabrication. Its probably not a good project for a first
timer. If you are planning to do it all on your
own without a kit and you have never welded
or fabricated anything, I would not recommend
it. You might want to find a local shop to help
with the fabrication and suspension geometry.
MOPAR 360 V-8 SWAP
How hard so you think it would be to fit

a ZJ 360 V-8 and transmission into a
classic Grand Wagoneer?
NAME WITHHELD
VIA EMAIL
fourwheeler.com
TECHLINE
A
I think its a totally doable and a smart

swap. Its actually a pretty easy swap,
too. However, I think youll be much better off
starting with a more common (and likely less
expensive) Dodge 1500, Dakota, or Durango
360ci V-8. Unfortunately, 98 was the only year
the Chrysler 360 V-8 was offered in the Grand
Cherokee. Not many 98 Grand Cherokee 5.9L
Limited models were built. All other ZJs with
V-8 engines have the 318ci V-8, which is also a
good swap. It just produces less power than the
360. Both Advance Adapters (advanceadapters.
com) and Novak Conversions (novak-adapt.com)
offer components that can help you swap the
Dodge V-8 under the hood of your FSJ. As long
as your Grand Wagoneer is from 80 or newer,
you could use the transmission and transfer
case from the Dodge, saving a bit on adapting
costs. The front and rear driveshafts will line up.
Earlier FSJs will require either a front and rear
axle swap or a transfer case swap.
Id recommend finding a Mopar drivetrain assembly that has a transfer case with a mechanical shifter linkage, as it will simplify the wiring
a little bit. You might even want to look for the
NV3500 five-speed manual transmission. It was
available in some Dodge trucks behind the V-8
and could make for a unique swap. You can find
more general info about the Mopar 360 swap at
fourwheeler.com here: bit.ly/1AHejze.
CAPPA QUESTION
Im installing a 1-inch-thick clevis-mount

tow point to my gusseted 316-inch bumper. The plan has been to pierce the bumper
so the tow point can be properly welded on
both sides. I was always of the belief that this
was the strongest way to solidly mount a tow
point or hitch. I recently had some people
recommend other methods. Any good input
on this?
JOHN CAPPA
VIA EMAIL
Max Gremillion of Premier Power Welder

(premierpowerwelder.com) responds:
Its kind of one of those things where

if you asked 10 carpenters to build you
10 cabinets, youll end up with 10 different
cabinets. One of two ways would be the best,

given the welders ability. The key factors are
always preheat and penetration. If it is to be
surface mounted, I would definitely recommend beveling and preheating. The most
optimal method is to cut hole for the tow point
and weld it from both sides. If a little is good,
a lot is better. Hopefully, the bumper can be
removed so you can make the weld in the flat
position. I always stress preheating because of
the difference in thickness of the base materials. That 1-inch-thick tab is one heck of a heat
sink and will draw a lot of heat. A 350 degree
preheat should be good.
WHY RUSTY ALREADY
I was reading Upping the Non-Ferrous

F-150 in the Aug. 15 issue about the
BDS lift kit for the 15 Ford F-150. The author
commented that with less than 100 miles on
the truck, there was already rust forming on
the driveshaft, CV axles, ball joints, and so on.
Is there any way someone at the magazine
can ask a higher up person at GM, Ford,
or Ram as to why this is happening on new
trucks and print their response? You would
figure that after spending roughly $35,000
or more for a decent new 4x4 truck, this
wouldnt be happening. Im sure if you see
one sitting new at the dealer lot, the parts
underneath are already rusted.
MIKE DUPLESSIS
MERIDEN, CT
I doubt that any of the OEs would even

want to officially comment on a question
like this. However, I do have some simple
explanations for the rusty components you
might find under new trucks. Spinning parts like
the driveshafts are welded together and then
balanced by welding on weights. You obviously
cant coat the surfaces prior to welding on
them. Painting, dipping, or spraying any kind
of coating on the driveshaft after the balancing
process could cause it to be out of balance and
lead to a vibration, however slight it may be. Of
course, painted driveshafts are incredibly common in the aftermarket world. However, keep in
mind that the OE standards are generally much
more stringent than in the aftermarket in some
cases. You may have noticed that many OEs
have begun using aluminum driveshafts in some
applications. The aluminum is not only lighter,
it improves drivetrain performance and doesnt
rust, eliminating the need to protect the surface
after welding. Other components such as ball
joints and CVs require a tight flush fit. Paint or
any other coating on the mating surfaces could
cause a problem during assembly or a misalignment of the parts. A little rust is a much better
option in my opinion. Ultimately, if the rusty
parts bother the owner enough, a $2 can of
spray paint can cover it.
PART-TIME TROUBLES
I have a 77 Suburban with a TH350

automatic transmission and an NP203
transfer case. It has the Mile Marker part-time
wedge-style conversion kit, but it continues to
fail. Is there a company that makes the shaftstyle conversion kit that Mile Marker used to
offer, or is there another transfer case that
can be swapped in as a direct fit?
NAME WITHHELD
VIA FOURWHEELER.COM FORUMS
Unfortunately, Mile Marker (milemarker.

com) no longer offers any of the part-time
conversion kits for the NP203. So whatever
is out there as new old stock is it. There are
probably a few dusty kits sitting on shelves or
on eBay (ebay.com). You may be able to locate
a used Mile Marker shaft-style part-time kit
in the wrecking yard, too. You could also try
Offroad Design (offroaddesign.com). The company specializes in converting the NP203 into
a doubler range box. The back half of the case
is not used in this adaptation, so there may
be a stack of part-time conversion kits stowed
away somewhere in the shop.
As for swapping out the NP203, its pretty
straightforward: You can simply unbolt the
NP203 and the adapter and bolt in the TH350
version of the part-time NP205 with the proper
factory adapter. You can locate these parts
at the local wrecking yard, or you can source
them through Offroad Design. The company
offers rebuilt NP205 transfer cases and adapters for every application possible. The NP205
is significantly shorter than the NP203, so
driveshaft modifications are required. The rear
driveshaft will need to be lengthened and the
front will need to be shortened. Youll also have
to mount shifters. You can make the factory
shifters work, or you can use the twin-stick
shifter kit from Offroad Design.
If you use the Suburban regularly in technical off-road terrain, you may consider utilizing
the range box portion of your NP203 for a
transfer case doubler. Offroad Design offers
the adapters and shifters required to bolt up
an NP205 to the back half of your NP203.
This will give you the transfer case gearing options of 1:1, 1.96:1, 2.01:1, or a double low
of 3.94:1. Again, this option will require driveshaft modifications. fw
fourwheeler.com
CALENDAR
COMPILED BY KEN BRUBAKER
KEN.BRUBAKER@FOURWHEELER.COM
February 6
What: Women Only Getting Started
Off-Road Driving
Where: Borrego Springs, California
Hosted by: Badlands Off-Road Adventures
Info: 310/613-5473, 4x4training.com
February 12-14
What: Sno*Blind
Where: West Branch, Michigan
Hosted by: Mudchuggers 4 Wheel
Drive Club
Info: mudchuggers.com
February 19-21
What: California Association of 4WD Clubs
Convention
Where: Rancho Cordova, California
Hosted by: CA4WDC
Info: cal4wheel.com
February 20
What: Getting Started Off-Road Driving
Where: Gorman, California
February 21
What: Sand Off-Road Driving
Where: Grover Beach, California
February 27
What: Getting Started Off-Road Driving
February 28
What: Day 2 Getting Started Off-Road
Driving
February 29
What: 4-Wheel Drive Instructor Training
Info: 310/613-5473, 4x4training.com FW
WHERE TO SEND
SUBMISSIONS
ddress your correspondence to:
Calendar, Four Wheeler, 831 S. Douglas
St., El Segundo, CA 90245, or email
ken.brubaker@fourwheeler.com. All submissions become the property of Four Wheeler,
and we reserve the right to edit them for length,
accuracy, and clarity. The editorial department
can also be reached through the website at
www.fourwheeler.com. Due to the volume of mail,
electronic and otherwise, we cannot respond to
every reader, but we do read everything.
fourwheeler.com
2011-2015 2500HD & 3500

5 2WD/4WD w/shocks .............$1393.74
2 Lift Kit ..................................... $159.95
2 Torsion Bar Leveling Kit............. $99.95
2001-2010 2500HD & 3500
6 2WD/4WD Lift w/shocks .......$1149.96
3 Adventure Series UCA Lift Kit .. $795.95
2 Lift Kit ..................................... $159.95
(01-10) Heavy Duty UCA Kit .............. $369.95
2 Torsion Keys .............................. $99.95
2007-2015 1500
4.5 & 6.5 4WD Lift w/shocks ......$1295.95
4.5 & 6.5 2WD Lift w/shocks ........ $999.95
3.5 Adventure Series UCA Kit............ $619.95
(07-13) Heavy Duty UCA Kit .............. $395.95
3.5 2WD/4WD Combo Lift............. $199.95
2 Lift Kit ..................................... $129.95
2 Leveling Kit ............................... $69.95
3 Body Lift ................................. $374.95
1.5 Body Lift ................................. $149.95
1999-2006 1500 4WD
6 4WD Lift w/shocks ................$1299.95
3.5 Combo Lift .............................. $249.95
2 Lift Kit ..................................... $149.95
2 Torsion Keys .............................. $99.95
3 Body Lift ................................. $307.95
1.5 Body Lift ................................. $159.95
1988-1998 1500 4WD
6 4WD Lift w/shocks ................$1195.95
2 Lift Kit ..................................... $149.95
2 Torsion Keys .............................. $99.95
3 Body Lift ................................. $176.95
1973-1987 CHEVY 1/2 & 3/4 TON PICKUP
1973-1991 1/2 & 3/4 TON BLAZER,
JIMMY, SUBURBAN
6 4WD Lift w/shocks .................. $599.95
4 4WD Lift w/shocks .................. $499.95
2015/2004-2012 COLORADO/CANYON
2.75 2015 - Combo Lift Kit .............. $205.95
3.5 04-12 - Combo Lift Kit............. $349.95
1.5 Body Lift ................................. $165.95
1.5 Leveling Kit ............................... $49.95
2 04-12 Leveling Kit..................... $99.95
2 Lift Kit ..................................... $149.95
2007-2014 SUBURBAN/TAHOE/YUKON
6.5 4WD Lift w/shocks ................$1739.99
2 Leveling Kit ............................... $69.95
2 Body Lift ................................. $319.99
1992-2006 SUBURBAN/TAHOE/YUKON
6 00-06 4WD Lift w/shocks ......$1679.95
2 92-06 Torsion Bar Keys .............. $99.95
2 92-98 Lift Kit.........................$149.959
3 Body Lift ................................. $199.95
Factory Direct Pricing

Free Freight to
Local Distributors
+
1500 4WD
6 2013-2014 4WD w/shocks .....$1519.95
4 2013-2014 4WD w/shocks .....$1409.95
6 2012 4WD w/shocks ..............$1519.95
4 2012 4WD w/shocks ..............$1409.95
3.5 12-14 4WD Combo Lift.............$659.90
2 12-14 Adventure Series UCA Kit$519.95
1.5 06-14 4WD Body Lift................$139.95
6 09-11 4WD w/shocks .............$1699.95
4 09-11 4WD w/shocks .............$1599.95
4 09-11 4WD Combo Lift.............$735.94
2.5 09-11 Adventure Series UCA Kit$595.99
06-11 Heavy Duty UCA Kit ..................$430.95
6 06-08 4WD w/shocks .............$1295.95
4 06-08 4WD w/shocks .............$1249.95
4 06-08 4WD Combo Lift.............$761.94
2.5 06-08 Adventure Series UCA Kit$595.99
3 06-08 4WD Body Lift................$355.95
5 94-01 4WD w/shocks ...............$839.95
2.5 94-01 Lift Kit............................$179.95
2.5 94-01 Leveling Kit......................$99.95
5 02-05 4WD w/shocks .............$1195.95
2 02-05 Lift Kit............................$149.95
2 02-05 Leveling Kit......................$99.95
2500/3500 4WD
6.5 14-15 2500 Radius Arm Kit ....$1345.99
6.5 14-15 2500 Lift Kit .................$1149.99
5.5 14-15 2500 Radius Arm Kit ....$1320.87
5.5 14-15 2500 Lift Kit .................$1124.87
4.5 14-15 2500 Radius Arm Kit ....$1159.95
4.5 14-15 2500 Lift Kit ...................$975.95
4 14-15 2500 Radius Arm Kit ....$1159.95
4 14-15 2500 Lift Kit ...................$975.95
2 14-15 2500 Leveling Kit .............$99.95
6.5 13-14 3500 Radius Arm Kit ....$1095.95
6.5 13-14 3500 Lift Kit ...................$899.95
5.5 13-14 3500 Radius Arm Kit ....$1070.83
5.5 13-14 3500 Lift Kit ...................$874.83
4.5 13-14 3500 Radius Arm Kit ......$999.95
4.5 13-14 3500 Lift Kit ...................$815.95
4 13-14 3500 Radius Arm Kit ......$999.95
4 13-14 3500 Lift Kit ...................$815.95
2 13-14 3500 Leveling Kit .............$99.95
8 03-13 w/shocks .....................$1329.95
6 03-12 w/shocks .....................$1105.95
5 09-13 w/shocks .......................$912.81
5 03-09 w/shocks .......................$770.95
5 94-02 w/shocks .......................$839.95
2.5 94-12 Leveling Kit......................$99.95
5
3
3
6
4
2.5
2.5
07-14 Tundra w/shocks...........$1299.94

07-14 Tundra Leveling Kit ...........$99.95
07-14 Tundra Lift Kit .................$169.95
05-12 Tacoma Suspension Lift $1249.95
05-12 Tacoma Suspension Lift $1195.95
05-11 Tacoma Leveling Kit ..........$99.95
07-11 FJ Cruiser Lift Kit .............$229.95
Learn more about the Factory Protection Plus Program at 560plus.com
ZONEOFFROAD.COM
888-998-ZONE
05-15 F250 & F350

6 Radius Arm Kit w/shocks ........$1279.95
4 Radius Arm Kit w/shocks ........$1053.48
4 4WD w/shocks ..........................$799.96
2 Body Lit (11-15) .......................$399.95
2 Leveling Kit.................................$99.99
1 Budget Boost ..............................$69.99
99-04 F250 & F350
6 4WD Lift w/shocks....................$995.95
4 4WD Lift w/shocks....................$809.95
2.5 Leveling Kit...............................$295.95
1 Front Shackles ............................$74.95
3 Body Lift (99-03) ......................$334.95
1997-2014 F-150
6 2014 4WD w/shocks ...............$1299.95
6 2014 2WD w/shocks ...............$1195.95
4 2014 4WD w/shocks ...............$1299.95
2 2014 4WD w/shocks .................$169.95
2 09-14 Leveling Kit ......................$99.95
6 09-13 4WD w/shocks..............$1549.95
6 09-13 2WD w/shocks..............$1399.95
2 09-13 Lift Kit ............................$169.95
6 04-08 4WD w/shocks..............$1399.95
4 04-08 4WD w/shocks..............$1299.95
2 04-08 4WD Lift Kit ....................$169.95
2 04-08 4WD Leveling Kit ..............$81.95
3 04-05 Body Lift .........................$365.95
6 97-03 4WD w/shocks..............$1295.95
2 97-03 4WD Lift Kit ....................$159.95
2 97-03 4WD Leveling Kit ..............$99.95
4 97-03 4WD Combo Lift .............$279.95
3 97-03 Body Lift .........................$199.95
2 97-03 Body Lift .........................$187.95
JEEP 07-15 JK LIFTS
2 Spacer Lift ................................$129.99
3 Coil Lift w/ shocks .....................$439.99
5 Coil Lift w/ shocks ...................$1299.95
2 Body Lift ...................................$119.99
JEEP 84-01 XJ LIFTS
2 Spacer Lift w/ shocks ................$251.46
4.5 Coil Lift w/ shocks .....................$495.95
3 Coil/Rear Leaf w/shocks............$510.94
4.5 Coil/Rear Leaf w/shocks............$749.94
JEEP 97-06 TJ LIFTS
2 Spacer Lift w/ shocks ................$229.75
4.25 Combo Lift ................................$529.99
1.25 Body Lift .....................................$94.95
2 Body Lift ...................................$108.75
3 Body Lift ...................................$114.22
JEEP YJ & CJ LIFTS
1.25 87-95 YJ Body Lift .......................$89.95
4 87-95 YJ Lift w/shocks ..............$625.95
2 87-95 YJ Lift w/shocks ..............$499.95
2 87-95 YJ Body Lift .......................$89.99
3 87-95 YJ Body Lift .......................$95.99
2 72-86 CJ Body Lift.......................$89.74
3 72-86 CJ Body Lift.......................$94.06
JEEP GRAND CHEROKEE LIFTS
2 93-98 ZJ Spacer Lift w/shocks...$218.62
4 93-98 ZJ Coil Lift w/ shocks.......$639.95
4 99-04 WJ Coil Lift w/ shocks .....$699.95
4 05-07 WK Lift .........................$1499.95
JEEP COMANCHE MJ
4.5 86-92 Lift Kit ............................$549.95
D143
MARKETPLACE TO ADVERTISE IN THIS SECTION CALL 310-531-5068
100%
American Made Axles
Americas Best Quality Axles & Gears

at Affordable Prices!
Strong Dealer Program
Huge Inventory
Top Notch Customer Service
Fast Same Day Shipping
Call Today For Your FREE
DVD!
Free DVD offer with purchase, while supplies last
TOLL FREE 855-957-0013
MAKE YOUR OWN PATH
MUD IT UP, KEEP IT COOL

EXHAUST
INSULATING
WRAP
Call (800) 274-8437 or
EXPRESS
SLEEVES TM
visit ThermoTec.com,
for a FREE CATALOG,
technical support, or
a distributor near you.
BATTERY
WRAP HEAT
SHIELD
REVOLUTIONGEAR.COM
MARKETPLACE TO ADVERTISE IN THIS SECTION CALL 310-531-5068
The
Essentials
Ultimate
Catalogs
for Jeep Vehicles
JUST Pick the FREE

Catalog YOU NEED!
ESSENTIALS for
41-06 CJ & Wrangler
Our NEW 316 page catalog
covers ALL 41-06 Classic,
MB, CJ, YJ, and TJ Wrangler
Jeep Vehicles!
FREE 41-06 Catalog

request code:
FWDNJ
NEW CATALOG
FOR 07-16 JK
Like us on
Expanded 304 Page catalog

for JK exclusively for your
07-16 Wrangler/Unlimited
Facebook!
www.facebook.com/fourwheelermag
For a FREE JK catalog

request code:
FWDNK
Catalog For
CHEROKEE Vehicles
Our NEW FREE 88 pg
catalog for Cherokee &
Grand vehicles from 84 -16
For FREE Cherokee

catalog request code:
FWDNX
this
Christmas!
free!
Q
Its a gift
youll BOTH love!
ScanMe!
With a smartphone QR reader
Over 200 premium

PJs, each with:
FREE
3HUVRQDOL]HGFDUG
1.800.GIVE.PJS
PajamaGram.com
Request your Preferred

Essentials catalog today!
6KRZQ5XE\9HORXU/RXQJH6HW
FREE.HHSVDNH
JLIWSDFNDJLQJ
888-745-9962
Mon - Thurs 8AM - 12AM, Fri 8AM - 9PM & Sat 9AM - 5PM EST
Everything Jeep
The terms Quadratec and Essentials are Registered Trademarks of Quadratec Incorporated, Registered at U.S. Patent and Trademark Office. Quadratec, Inc., an independent supplier of accessories
for sport utility vehicles, has no affiliation with Fiat Chrysler Automobiles (FCA). The terms Jeep, Wrangler, Rubicon, Unlimited, Mopar, Cherokee, and the Jeep Grille Design are registered trademarks of FCA
and are used for identification purposes only. 2015 Quadratec Incorporated.
TRAILS END
BY KEN BRUBAKER KEN.BRUBAKER@FOURWHEELER.COM PHOTOGRAPHY: BILL DELANEY
March 1999:
Turbodiesel Concept Power Wagon
anufacturers trot out concept rigs to gauge, among

other things, the buying
publics reaction. Some
concept rigs make it into
production, and some just disappear. One
concept that didnt make it into production,
but should have in our opinion, is this Power
Wagon we featured in the Mar. 99 issue of
Four Wheeler. We had a chance to inspect
and drive the rig prior to its debut at the 1999
Detroit Auto Show.
The truck was designed to reflect the rugged, purposeful look of the original Power
Wagon, but with modern industrial touches
and innovations. Under the hood was a
common-rail 7.2L I-6 turbodiesel engine that
was fed sulphur-free fuel and produced 250
hp and 780 lb-ft of torque. We noted that
the Cummins I-6 found in the Dodge trucks

at the time delivered 450 lb-ft of torque. We
were underwhelmed by the concepts engine,
however. Why? Unfortunately for us, the
Concept Power Wagon was (like many concept vehicles) tuned for reduced power and
felt equal to a normally aspirated six-cylinder,
we wrote. Detuning aside (we called it journalist mode), we noted, It did, however,
sound quite robust, not unlike an 18-wheeler,
and we suspect the torque numbers quoted
for this concept hint at whats in store for future Ram owners.
Engine power was routed
through a Ram 2500-sourced
47RE four-speed automatic transmission and a full-time manualshift NVG 242 transfer case with
PTO capability to split power to
the axles. The Power Wagon chassis was

based on the Ram 1500 of the time, and up
front was a Dana 44 axle with Dodge Viper
four-piston brake calipers and vented discs,
while aft was a Chrysler 914-inch axle that was
equipped with Viper vented discs and singlepiston calipers. Both axles had a differential
ratio of 3.90:1. Unlike the Ram 1500 of the
time, which had coil springs up front and
leaves out back, the Power Wagon used a
five-link suspension setup front and rear with
coilover shocks. The link-arm design is con-
UNDER THE HOOD WAS A COMMON-RAIL 7.2L

I-6 TURBODIESEL ENGINE THAT WAS FED SULPHUR-FREE FUEL AND PRODUCED 250 HP AND
780 LB-FT OF TORQUE.
ventional Ram up front with stout reinforcing
underneath the control arms. In the rear,
reinforced control arms from a production
ZJ locate the axle, we wrote.
Inside, the two-seat rig had two-tone
leather throughout; contrasting finishes
of billet aluminum, European ash wood
and raw steel; and a panel of drawers in
the Quad Cab area. Outside, there were
functional cooling slots in the hood, the
cargo bed was wood-lined, and there was
a power-operated tailgate.
But thats not all. The Power Wagon
features also included 35-inch tires, a minimum ground clearance of 912 inches (20
inches at the running boards), and a massive winch (with dash-mounted controls).
Theres a few things wed change, but
overall, the Concept Power Wagon was
pretty darn cool. Unfortunately, it was one
of the concepts that never went into production and just disappeared. fw
FOUR WHEELER (ISSN 0015-9123) February 2016; Vol. 53, No. 2. Published monthly by TEN: The Enthusiast Network, LLC, 261 Madison Avenue, 6th Floor, New York, NY 100162303. Copyright 2015 by TEN: The Enthusiast Network Magazines, LLC. All Rights Reserved. Periodicals postage paid at New York, NY and at additional mailing offices. Single copy price
is $5.99. SUBSCRIPTIONS: U.S. APO, FPO and U.S. Possessions $19.97 for 12 isssues. Canada orders add $12.00 per year and international orders add $24.00 per year (for surface
mail postage). Payment in advance, U.S. funds only. POSTMASTER: Send all UAA to CFS. (See DMM 707.4.12.5); NON-POSTAL AND MILITARY FACILITIES: Send address corrections
to FOUR WHEELER, P.O. Box 420235, Palm Coast, FL 32142-0235.
fourwheeler.com
DOOR PANELS
1947-1994 CHEVY/GMC Trucks & SUVs
1951-1991 Ford Trucks & SUVs
Need Handles, Trim or Armrests?

Check out our Free Detailed Catalogs, Go Online 24/7 or Call Today!
Parts & Accessories for Trucks & SUVs

1947-13 Chevy/GMC 1948-15 Ford 1972-15 Dodge
2015 Long Motor Corp.
800-562-8782
LMCTruck.com

Four Wheeler - February 2016

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Four Wheeler - February 2016

Uploaded by

Copyright:

Available Formats

FIRST LOOK!

THE NEW 2017 FORD SUPER DUTY

THE WORLDS LEADING 4x4 AUTHORITY

TOP TEN THINGS

DIESEL COLD START CURES

Snow, Ice & Wet

Long Wear, Comfort

#ANYWHEREISPOSSIBLE // LIKE US ON FACEBOOK.COM/GENERALTIRE

FEBRUARY 2016, VOL.53, NO.2

101 LOW-BUDGET TIPS & TRICKS

FEATURES & EVENTS

TECH & HOW-TO

7 FIRING ORDER / 8 INBOX /

Correcting common 4x4 errors

56 CUMMINS COLD SHOULDER

Brake Upgrade Kits

SIX FABULOUS CHOICES

Managing Editor Lee Lovell

These rotors WILL NOT RUST

ART DIRECTION & DESIGN

NRS - NUCAP Retention System

Ask at Pep Boys

Canada Post: Return undeliverable Canadian addresses

Associate General Manager Kurt Miller

Accessories Available for

Hitch Mounted Bumper Protection

uitting time! I swiveled my chair

the time. No sooner had I noted it was 5:03

simple gadget caused this professional to

FIRST DRIVE: RAM REBEL OFF-RO

THE WORLDS LEADING

WICKED OFF-ROAD RANGER

POWER & TORQUE

OCTOBER 2015 $5.99

BY CHRISTIAN HAZEL CHRISTIAN.HAZEL@FOURWHEELER.COM

SHORT AND SWEET

diameter oak dowel rod to mount three rolls

8 FEBRUARY 2016 FOUR WHEELER

requirement was that there had to be some

SHOP BY VEHICLE OR TALK TO AN EXPERT

American Racing AR23

B.R. 937 Type 8P Steel

Granite Alloy GV8

Granite Alloy GA640

KMC XD XD823 Trap

WORX 806 Triton

2015 Tire Rack

MC XD XD822 Monster II ATX AX198 Chamber II

Ultra Xtreme X-Lok

M-F 8am-8pm EST

W. E.R. 504 Legacy

and four-seaters. Platforms will be

we will be getting the diesel Wrangler and the Wrangler pickup:

The most sought-after used

10 FEBRUARY 2016 FOUR WHEELER

Photography: Courtesy of the Manufacturers

Could it be true that the Jeep Grand

Land Rover, can we like this diesel

High quality monotube

2016 Jeep Wrangler Black Bear and Two New Mopars

On the Mopar side of things, theres the

Traffic Safety Administration is too

Range Rover Sentinel

ts a first, as in the first armored Land Rover engineered by its