Third Times a Charm 93 Eagle Talon AWD

[airmail96]

So I had a build going in the old journal system before the new one got implimented, but just hadn't taken the time to move everything over to the new system, but today I have some spare time so hopefully I can get everything moved over to here. My plan is to have the main post updated with links to various updates I make in the post for easy categorization.

Return from deployment and Parts list.
Slight Interior Deconstruction
Removing things from the motor

Hey guys what's going on? I just joined this forum and thought I would throw my build up on here even though I am currently stuck on deployment. The reason for the title is this is my third DSM, I lost the first two to accidents so I figure I would give them one more try and if I wreck this one then it's just not ment to be. The car is a 93 Eagle Talon TSi AWD here it is when I picked it up

Buschur Stage 1 Block Walbro 255 Hard Upper and lower intercooler pipes Knock Off BOV 2g Mass 550cc injectors Motegis Spray painted copper 16g Turbo (not sure on the size) Bushchur 2.5in Exhaust 2.5 Atmospheric dump Reverse pops out, and the e-brake doesn't work . Shortly after I got it home I noticed a leak comnig from the transfer case didn't really think anything of thought maybe it was over filled, being my first AWD I just kind of drove it around fillnig it up occasionally and then looked into the recall, got the recall performed (Brand New t-case from the dealer) about 6 months later as I was halfway home to West Virginia I start hearing a horrible sound, needless to say ran the t case dry causing complete an utter chaos inside metal shavings everywhere inside. Got a new T-case and that one too was leaking so I knew it had to be something specific to the car I searched around and found the T-case recall kit. This is what my old yoke looked like.

With the new yolk on there was no more leaks, go figure I wish I would have done that one a long time ago, not really sure what I was so afraid of. While I was under there I went ahead and installed the aluminum driveshaft support bushings, didn't really notice anything different between them and the old ones. The next thing that happened to her was one day while getting gas I noticed something leaking underneath the car from the driver side right behind the rear tire, squated down touched it and smelled it low and behold it was gas. So I drive back home and start looking around, come to find out the feed line coming off the sending unit had rusted so bad it was leaking I tried to patch it with some JBweld with no luck.

At this point I decided to say screw it, so I surfed on over to STM and bought the Full Blown Motorsports Dual pump intank setup with their -6an tank to rail kit, figured I never wanted to go through this again . When I recieved the Full BLown kit I was kind of suprised at just how simple the thing was. Looking back at this purchase I wish that I would have gone with the Buschur double pump unit just for the simplicity of the wiring.

Luckily I managed to get the old sending unit out without snappnig a single nut or anything, but while installnig the new one well lets just say I broke 5, so for the time beign the car constantly has a gas smell yummy.

.
I also took the time to go ahead and wire up my new Prosport boost and oil pressure guage.

night time

day time

off.
After all of that I just drove the car around fixing the little odds and ends until, one day after doing a third gear pull as I was slowing down I heard a thunk and something dragging, after pulling over I looked udner the car and saw this. WTF

Yup T-case took a chunk out of my bell housing and dropped on the ground still attached to the driveshaft. At that ponit I decided it was time to build her I had just moved in with a friend from the ship and he offered to let me use part of his garage (shame on him). I don't know how some of you guys get your transmissions out so fast. There was so much rust build up on the shock towers it was insane it was my first time ever using a propane torch to break bolts loose though I wish I would have discovered how well that stuff works sooner. The passanger side had been taken loose before, but the drivers side looked like it had never been touched.

As I was working my way through the rust I started to accumulate parts: Avid Racing Motormounts (Driver, passanger, rear), Arp head studs, Spearco Core intercooler, AEM Tru-Boost, Tial Q Bov, Jays Racing Alternator relocation kit, Walbro 255, Prosport AFR Wideband, Coolant Temp, Voltage gauges and then I got sent on deployment 4 months early the only thing that I was able to do before we left was Install the transmission back in with the avid racing mount and wire up the guages in the interior and hook up the tru-boost.

Jackstand racing :-( Since I have been out I have acquired some more parts: FP2 cams, Hawver Intake Manifold, JMFab Fuel Cell, JMFab race support bumper, Tial MV-S, 1680cc Fic Hi-z injectors, Passanger side knuckle, shifter cables, and ebrake cables. For tunning I plan to use my DSMap/Werewolf SD setup that I had from my last DSM. Also plan on running E-85 since we have a couple stations that sell it around where I am stationed at.

 

[dsmgst1996]

Thank you for serving our country and nice 1g

 

[91stocker]

So how was the install on that dual pump hanger? Its a great looking piece.

 

[airmail96]

Nov. 2011
So I am almost a month away from returning and getting started on this thing, since I have been gathering parts and stuff I keep telling myself that I am done buying parts, but it seems like every time I get to surfing the internet I see something else that I want. So here is my overall parts that i have collected and waiting for me when I get home.

This is what I came home too

Calan Custom Catch Can -8an inlet/ -10 an outlet
AEM Tru-Boost with 5 bar map sensor
Vassil Chromoly 3pc Cross Member
ARP Headstuds
FP2 (272/272)
Valve Cover with 2 -8an outlets
3" Driveshaft Shop Aluminum Driveshaft
Non-cruise throttle cable, AEM Cam Gears, IBM laptop
Avid Racing Motor Mounts
Megan Racing 3in exhaust (DP, Test Pipe, and Catback)
Holset HX-40 8-blade billet, 18cm t3 divided housing
-6an tank to rail line with -6an Fuel Lab Fuel Filter
Fuel Pump Rewire Kit
ABS delete kit, -6an return line kit, Metal FuelLab Fuel Filter, Fic Viton seals
Walbro 255lph
1680cc Hi-z Fic injectors with resistor pack delete
ETS front Mount Piping Kit
Tial MVS Wastegate
JMFab Aluminum Race Bumper
Hawver Cast Aluminum Intake Manifold
Prosport Wideband AFR Kit (Guage and sensor)
Mishimoto Radiator with 2 12" Fans
Tial Q BOV
Sparco FMIC core
Holset Oil Feed Kit
Turbo 10an oil return line kit for Holset
JMFab 7 gallon Fuel cell
Jays Alt. Relocation Kit
Full Face Southbend TZ/FE with SS 2300LBS PP
DGR Track Coilover
Redjack Racing T/S T3 manifold
Redjack Racing Vband 02 eliminator DP

March 3, 2012
Heres a picture of the back end of the Jeep loaded up with everything i gathered during deployment. This was taken as we were moving into the new place.

In this picture you will notice an old looking tubular manifold and a V-Band 02 housing. This was taken back when I was planning to run a Holset HE351VE VGT towards the end of deployment I decided to go a different route and picked up the T/S HX-40.

Heres a picture of her on her way to the new house.

Heres a picture of her after she got moved into her new home, you can tell she has been sitting for awhile with all the dust that has built up on her :-(, 11 month deployment will do that to you I guess

Thank you for serving our country and nice 1g

Thanks man, glad to do it.

So how was the install on that dual pump hanger? Its a great looking piece.

The install honestly wasn't that bad, I think the hardest part was trying to keep from snapping all the studs holding it in because of all the rust that was back there. The top sits a little to high though so I can't put the fuel pump acess plate back down though I tried different 90s with no luck.

 

[airmail96]

I don’t have major plans for the interior I originally planned on gutting it, but eh maybe later on down the road for now though the backseat has to stay in for my son so he can ride with me. So that is why there isn’t really much to throw in here.
After moving the Talon to the new place the real fun began. I started by First empting out all the crap that I had placed in in the interior, everything from parts to just miscellaneous trash.

Once I had the parts and crap out I removed the driver seat so I had better access to things underneath the dash and I also removed the back seat, in doing so I found some rust lurking underneath there also found some on the legs of the driver side seat so I made note of both of those.

(Back Seat)

(back seat close up)

(Driver Side chair)
After removing the chairs and everything I removed the center console since I planned on replacing my shifter cables, at this time I also removed my ECU just o make sure it was an eprom and to make room for my already chipped ECU that has ds-map on it. the ecu I pulled out looked to have a little bit of damage from cap leakage but nothing unfixable.

 

[duper15597]

Where did you find the ABS delete kit?

 

[airmail96]

I bought the abs delete kit from STM. Includes the non abs valve fittings and hoses to go to the brakes.

http://www.streettunedmotorsports.com/parts/stm_dsm_1g_abs_delete_kit.htm

 

[CRASH313]

That's a hole lot of gathering nice great build keep it coming.

 

[airmail96]

After I got done removing the things I wanted from the interior I turned my attention to the motor. It’s interesting the things you find out about your car as you pull things off of it. I started by taking off the SMIC, as I was taking out the core I noticed something different about the outlet pipe I noticed that it said Greddy on it I got all excited thinking this whole time I was running a special Greddy SMIC. Upon posting it in the for sale section I was informed that it is just a stock SMIC with a Greddy 2.5” outlet pipe welded onto it.

Also found out that the pipe that went to the hot side was just what looked to be an old piece of exhaust pipe, I didn’t bother taking a picture of that. I moved on to taking off the intake manifold and throttle body, that went a lot smother then I thought it would, seemed like there was a lot of oil in there though.

Needless to say I have a calaan catch can going on maybe that might help with things a little bit. I also pulled the resistor pack for the high z injectors that I have going in. When pulling off the throttle body I had this little guy come off I think it connects to the TPS any ideas?

After getting the intake manifold off I went ahead and pulled off the exhaust manifold, the B16g turbo, intake pipe, and alternator which got the engine to this point.

I also removed the front bumper, crash beam, head lights, and hood to make it easier to get to things.

Before

After