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Tracker Body Removal- PICS and STEPS

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Offline tonyman246

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Tracker Body Removal- PICS and STEPS
« on: March 24, 2010, 03:00:08 PM »
I didnt start this project with making a writeup in mind, but i thought i might share some of my experience with you. This way if you are contemplating taking the body off of the frame you know what your in for. I started disconnecting things from the rear then moved toward the front then to the motor.
<br>
1. Unbolt the gas filler neck.
<br>
2. Remove wires from fuel pump.
<br>
3. Disconnect emergency brake lines from inside cab.
<br>
4. Remove wire on rear differential. (not sure what its called) And remove axle vent tube.
<br>
5. Remove speed sensor from trans.
<br>
6. Disconnect steering shaft.
<br>
7. Remove shift boots.
<br>
8. Disconnect ignition coil from distributor.
<br>
9. Unplug O2 sensor.
<br>
10. Disconnect brake booster vacuum line.
<br>
11. Disconnect heater core hoses. (may need to drain radiator to keep from dumping a lot of fluid)
<br>
12. Disconnect MAP sensor vacuum hose
<br>
13. Remove brake line and clip from inside driver fender.
<br>
14. Remove ground wires from coil
<br>
15. Remove either computer OR unplug all wires from engine.
<br>
16. Disconnect throttle cable from motor.
<br>
17. Disconnect clutch cable.
<br>
18. Im sure there are steps i didnt encounter that you might. this was just how my 1991 2 door tracker 1.6L 8v came apart.
<br>
The reason i did this was so i can work on the frame and do all my armor and bumpers and rock sliders with the frame off. I will also try to re route all the wiring so it will be a little less likely to get wet. It took 4 hours with me working and my friend handing me tools. All and all, wasnt too bad of a job.
<br>
ALSO IM LOOKING FOR SOME IDEAS ON WHAT TO DO. AXLES, MOTORS, DRIVETRAIN, ANTHING. what would you do if it were broken down like this?

1991 Geo Tracker 33" super swampers + 4" lift + minor fender trimming + locker = unstoppable!

*

Offline tonyman246

  • 58
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  • Gender: Male
  • I Love ZUKIWORLD!
Tracker Body Removal- PICS and STEPS
« Reply #1 on: March 24, 2010, 03:04:50 PM »
I didnt start this project
with making a writeup in mind, but i thought i might share some of my
experience with you. This way if you are contemplating taking the body
off of the frame you know what your in for. I started disconnecting
things from the rear then moved toward the front then to the motor.
<br>
1. Unbolt the gas filler neck.
<br>
2. Remove wires from fuel pump.
<br>
3. Disconnect emergency brake lines from inside cab.
<br>
4. Remove wire on rear differential. (not sure what its called) And
remove axle vent tube.
<br>
5. Remove speed sensor from trans.
<br>
6. Disconnect steering shaft.
<br>
7. Remove shift boots.
<br>
8. Disconnect ignition coil from distributor.
<br>
9. Unplug O2 sensor.
<br>
10. Disconnect brake booster vacuum line.
<br>
11. Disconnect heater core hoses. (may need to drain radiator to keep
from dumping a lot of fluid)
<br>
12. Disconnect MAP sensor vacuum hose
<br>
13. Remove brake line and clip from inside driver fender.
<br>
14. Remove ground wires from coil
<br>
15. Remove either computer OR unplug all wires from engine.
<br>
16. Disconnect throttle cable from motor.
<br>
17. Disconnect clutch cable.
<br>
18. Im sure there are steps i didnt encounter that you might. this was
just how my 1991 2 door tracker 1.6L 8v came apart.
<br>
The reason i did this was so i can work on the frame and do all my armor
 and bumpers and rock sliders with the frame off. I will also try to re
route all the wiring so it will be a little less likely to get wet. It
took 4 hours with me working and my friend handing me tools. All and
all, wasnt too bad of a job.
<br>
ALSO IM LOOKING FOR SOME IDEAS ON WHAT TO DO. AXLES, MOTORS, DRIVETRAIN,
 ANTHING. what would you do if it were broken down like this?

1991 Geo Tracker 33" super swampers + 4" lift + minor fender trimming + locker = unstoppable!

*

Offline tonyman246

  • 58
  • 0
  • Gender: Male
  • I Love ZUKIWORLD!
Tracker Body Removal- PICS and STEPS
« Reply #2 on: March 24, 2010, 03:06:48 PM »
I didnt start this project
with making a writeup in mind, but i thought i might share some of my
experience with you. This way if you are contemplating taking the body
off of the frame you know what your in for. I started disconnecting
things from the rear then moved toward the front then to the motor.
<br>
1. Unbolt the gas filler neck.
<br>
2. Remove wires from fuel pump.
<br>
3. Disconnect emergency brake lines from inside cab.
<br>
4. Remove wire on rear differential. (not sure what its called) And
remove axle vent tube.
<br>
5. Remove speed sensor from trans.
<br>
6. Disconnect steering shaft.
<br>
7. Remove shift boots.
<br>
8. Disconnect ignition coil from distributor.
<br>
9. Unplug O2 sensor.
<br>
10. Disconnect brake booster vacuum line.
<br>
11. Disconnect heater core hoses. (may need to drain radiator to keep
from dumping a lot of fluid)
<br>
12. Disconnect MAP sensor vacuum hose
<br>
13. Remove brake line and clip from inside driver fender.
<br>
14. Remove ground wires from coil
<br>
15. Remove either computer OR unplug all wires from engine.
<br>
16. Disconnect throttle cable from motor.
<br>
17. Disconnect clutch cable.
<br>
18. Im sure there are steps i didnt encounter that you might. this was
just how my 1991 2 door tracker 1.6L 8v came apart.
<br>
The reason i did this was so i can work on the frame and do all my armor
 and bumpers and rock sliders with the frame off. I will also try to re
route all the wiring so it will be a little less likely to get wet. It
took 4 hours with me working and my friend handing me tools. All and
all, wasnt too bad of a job.
<br>
ALSO IM LOOKING FOR SOME IDEAS ON WHAT TO DO. AXLES, MOTORS, DRIVETRAIN,
 ANTHING. what would you do if it were broken down like this?

1991 Geo Tracker 33" super swampers + 4" lift + minor fender trimming + locker = unstoppable!

*

Offline BRD HNTR

  • 2300
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  • Gender: Male
Re: Tracker Body Removal- PICS and STEPS
« Reply #3 on: March 24, 2010, 07:24:35 PM »
Nice start, and thanks for the information.  What are YOU trying to do/make?  The world is yours.

I would
Put rock sliders on the body.  http://www.zukiworld.com/forum/build-diaries-how-to-diy/tracker-2x4-rockers-frnt-bmper-4-dr-sprngs-lwered-frnt-diff-$30-steel-frnt-diff/
Install a longer swing 4 link suspension in back.
Do a 2" frame chop and drop (if you are staying with IFS).  Then I would take two inches out of the strut towers, and install GV springs in front.
And to spend the money you saved by doing this yourself, I would get a tc doubler (your choice).

Keep us posted with your progress.
93 Tracker,XL7 springs & 1" raised spring pads in front with YJ springs in back, home built bumpers rear & front (w/winch), 2" x 4" rock tubes,  ARB front & rear, converted Sami rear to IFS, 33x12.5x15  aluminum rims, roll cage, 2.7L w/5 speed auto.