Well, I went to install my twin pot calipers and new rotors and discovered that I did not have both brake line parts from the hard line to the caliper. Also, since the calipers are 2g, I needed the banjo-bolt style. I ordered a Stop-Tech set from amazon for $27 shipped:
I installed them, and when bleeding the fronts, we were not getting fluid to the fronts. Seems my supposedly clean hard brake lines were not that clean, so when bleeding we pushed junk into the stainless lines. After lots of brake clean and several super-stomps, the lines cleared and they were good:
After installing the new clutch master/slave and bleeding the system, I Was verifying the shifter was adjusted correctly and discovered that 5th and Rev were non-existent, even without the cables. Soooo, seems something was broken in it. So, I took my old spare 22-spline 90 tranny to a friends to swap out the output shaft to a 23-spline. Well, it took 45 minutes of prying and hammering to get the axle out that was stuck in it. They used the wrong axle and it wedged the cir-clip in it when it broke off some of the end splines inside the open diff. Well, that compressed the center case a bit, se we decided to replace the center case. Yea, 4 bolts snapped off during dis-assembly. But, once it was opened up, we discovered a couple issues but also some good stuff. BAD: staked nut for 5th gear backed off and was only on with 2 threads, a hole in the top xfer case bolt hole (just under the speedo mount) and a chuck of metal that matched that hole. The GOOD: The gears look fantastic, especially 1 and 2, which are notorious for issues in early 90 trannys, the syncros are a little sticky (maybe oil will help hear once installed and filled) for 3/4, A little more play then we would like in the shift forks but they are still in great condition. We extended the detente springs to get some more snap in there and torqued everything down to spec. FYI, the government changed our pennies. Pre 2000 pennies happily handle 109ft/lbs without running through 5th/rev in pieces, where as 2000 and newer only handle about 70). Tranny is much happier now, and has a 23-spline output-shaft so I can use my fresh xfer case. She just needs some de-greaser and paint to go back in. Thankfully I never filled the tranny with gear oil, so it will be a quick 20 minute swap.
I also got the factory intercooler pipe routing all shored up thanks to JNAVA sending me the GVR4 j-pipe. She is soo close to being finished.
Pre-intercooler piping correction. As you can see, I really needed the stock VR4 j-pipe: