Isuzu Trek Members Infoletter #47
June 2024
Welcome to Isuzu Trek Infoletter #47.
The I-Trek infoletter mailing list is managed in a Google Group: (https://groups.google.com/forum/#!forum/i-trekinfoletter). If you would like to be included in this exclusively Isuzu Trek group please request inclusion in our mailing list or e-mail the editor Bret Medbury for info at isuzutrek (at) gmail.com or islandduo (at) comcast.net. If you would like more detailed/higher resolution photos of any of the included ones please e-mail the original creator.
You should all be aware that a fantastic new resource for I-Trek owners has been added to the treasure trove of info on the Northwest Trek Fun Club website. Finally, with the help of John Herold NWTFC Webmaster, “we” (mostly he) has gotten the complete Isuzu NPR parts list posted. www.nwtfc.com/isuzu-infoletters/isuzu-trek-documents/ It contains every chassis part part number, right down to the screws and wire clips. My experience sez once you have a correct part number you can find the part. It is a large PDF file; I suggest you download it once then just keep it on your computer for ready access.
If you have any questions or would like more detailed photographs related to any of the below articles please contact the originator directly. E-mail addresses are provided for that purpose With an (at) replacing the ampersand @..
Index:
New Alternator and Electric Vacuum Pump
Big Al and Marcia
Exhaust Manifold crack and turbo issue
Ken
New Bed Motor
Bret and Laura
Major Oil Leak and scare
Bret and Laura
Manual Control of Glow Plugs
Pat
The Elusive Fuel Screen Strikes Again
Al and Marcia
Really Nice 1994 Makeover
Dave
Breakdown in Davidson SK Canada
Eric and Michelle
Water Heater Quick Drain:
Dana and Cheryl
Dry Wood Termite Invasion
Pat
Loose Alternator and Resultant Bad Wear
Bruce
+++++++++++++++++++++++++++++++++++++++++++++++
New Alternator and Electric Vacuum Pump:
Al and Marcia Glick aglicknmex(at) gmail.com
For those that do not know Al and Marcia have added (upgraded) their stable of Safari rigs with a 1991 2600. This modification applies to that rig and was swiped by myself from a posting on Trek Tracks cuz I thought some of you might be interested.
Al was having alternator troubles and the vacuum pump is mounted to the back of the original alternator, he wanted a more readily available alternator, however what to do about the vacuum pump?
First Al Chose a Hitachi alternator available here REMAN ASC POWER SOLUTIONS HITACHI ALTERNATOR 12V 70A – A441259 (ascautoelectric.com) which featured similar mounting characteristics and was readily available. Next he replaced the engine driven vacuum pump with an electric one activated by an adjustable vacuum sensing switch. The pump a Hella UP28 Universal Electric Vacuum Pump is very robust as it is intended for brake booster use. It was mounted on the driver’s side firewall frame very near the vacuum reservoir.
Exhaust Manifold crack and turbo issue:
Ken Harmon isuzutrek(at) aol.com
This is the third exhaust manifold on my Trek. They seem to crack about every 100,000 miles and I was past due for the third manifold as we approached 320,000 miles. I was watching it close but did not see a crack. Then on a pre-travel inspection I swiped my finger under the turbo heat shield and came back with the gray/black exhaust residue and knew there was a problem. Closer inspection disclosed a crack in the upper center of the exhaust manifold. When we got home I purchased a new manifold and began looking for a shop that would replace it for me. Several years ago my local Isuzu dealer said they would no longer support the older Isuzu’s with parts or maintenance. I began calling and visiting local shop and found none of them wanted to take the job. Eventually I found a retired truck road service mechanic who would do the job at our house. He charged $125/ hr, and charges start when he got in his truck to drive to the house, + $2 per mile.
Turbo replacement
With the exhaust manifold replaced we loaded up and departed on our summer trip. We were less than 2 miles down the road when problems with the repair started to become apparent. Our first indication was a very loud, very high pitched squeal as the turbo spun up. We returned to the house, jacked up the coach began to investigate the work that had been done.
Removing the inlet duct to the turbo and looking at the face of the impeller, the leading edge of one blade was bent backward. From the web, I found one of the symptoms of a turbo failure is a very loud high pitched squeal (like multiple sirens). Apparently the mechanic had failed to clean the ducts as he reassembled the turbo system. I disassemble the turbo system and found several problems (5) with the work that had been done on the exhaust manifold and reassembly of the turbo system. I started searching for a used or re-manufactured turbo.
General notes about working on the turbo system. I jacked up the coach using the front hydraulic jack along with a wood block stand that will raise the front tires about 10″ off the ground (the trailer hitch was touching the ground in back of a 24′ Trek). For safety I use a metal sleeve over the extended jack shaft so it could not retract. Then I add jack stands under both sides of the front axle for additional safety. When you remove the left front wheel and turn the steering wheel all the way to the right it will create a cavity large enough you can roll a caster stool into the opening and be out of the weather. Most of the work on the exhaust manifold and turbo can be done from this location. I would suggest cutting the toe ends off some old winter socks, put the socks on your arms to save some skin.
New or re-manufactured turbos are no longer available from the Isuzu parts network. The last ones they were selling were over $2,000. I ended up buying a re-manufactured turbo from Turbocharger Direct for a little over $800 after returning the core for credit. They claim to use all OEM Garrett parts in the new core assembly. On the web you can find “rebuilt” turbos for $150, some of them look like the rebuild was painted on in China.
A new air filter was installed, the oil & filter was changed, all the ducts and flexible hose connections were cleaned, and the intercooler was inspected with a remote TV camera with no foreign debris found. The only contamination I found was small flakes in the metal duct upstream of the turbo compressor inlet. My best guess is the mechanic laid the inlet duct on the ground allowing a small stone to get inside, when we drove the coach and the turbo spun up to operating speed, 125,000 rpm, the object hit the turbo blade, bent it throwing the turbo shaft out of balance causing the turbo to fail and a few small chips to go back up the duct. A black sticky deposit had accumulated over the years inside the duct downstream of the turbo compressor. When it was cleaned, no contamination was found in the cleaning fluid. No metal was detected upstream or downstream of the turbo.
New Bed Motor:
Bret and Laura Medbury islandduo(at) comcast.net
Laura and I departed Whidbey Island on Thursday Jan. 4, first morning on the road, hit the up switch on the bed and it starts going up, but makes this really uncomfortable sounding hard to describe noise (maybe groaning). Next night bed sounded normal going down, but again bad going up. Next day it sounds bad going both directions, and now includes a clicking sound. I have a spare motor.
Laura and I were planning to visit DickK93 near Sacramento anyway so we called and asked for help (really did he have a choice?), but he responded with “Sure, I’ll watch” I did not have all the tools especially if the tube needed modification and it did. Took a good part of the day, but we got it changed and learned an important lesson in the process. The motor installed is a AHT brand motor (Advanced Hurricane Technologies) from Shutter Motor Service in Florida Hurricane Shutter Repair & Service in Naples – Shutter Motor Service Their instructions clearly state which adjustments are for the up and also for the down limit switches. As installed the motor hit it’s UP limit switch when the bed was about 1/3rd of the way up, adjust the up limit, no change, adjust it MORE, no change. Finally after a bit of head scratching we discover that “UP” in a hurricane shutter is not necessarily “UP” in Electromagic bed. Yup up is down and down is up when this brand motor goes in your bed.
Major Oil Leak and scare:
Bret and Laura Medbury islandduo(at) comcast.net
The morning after the above bed repair Laura and I say our goodbyes start out of the driveway when I see this man behind me frantically waving. Yup that was Dick who runs up to the driver’s window to inform us that we are leaking oil BIG time. Holy Shazbotsky!!! I need help Dick!! inspection quickly revealed the cause was a loose oil filter. Less than a 1/4 turn stopped the leak, however we removed it checked the seal was OK then reinstalled. Let me tell you it is wicked tight now 🙂 way beyond that 1/4 turn. What a mess we made of his beautiful white driveway though 🙁 🙁 🙁
This was not leaking when we arrived so theory is that morning cold start and the vibration associated with starting a cold “old school” diesel rattled the filter loose. For those not familiar these filters are large, about 1/2 gallon and fairly long. I was the installer of the filter. You can bet they will be in the wicked tight category from now on. All Isuzu 4BD-2TC engines have this filter the 4BD-1T engines have two smaller filters.
This was a serious scare. If this leak had developed elsewhere we might easily have destroyed an engine. I am also partially at fault, not only for failing to get the filter tight enough, I mean it did last 800 miles, but I had violated my normal morning departure routine. Every morning after the Trek is started, I turn on all the exterior lights then do a complete walk around checking for any sign of leaks, all the lights working? TV antenna down? Compartment doors closed Etc. Etc. That morning I socialized, said our goodbyes and did not do that. It could have been a very costly oversight if it were not for Dick’s eagle eye.
Manual Control of Glow Plugs:
Pat Schumacher patschum(at) yahoo.com
Pat’s Glow Plug Controller developed a very ornery personality failing to work from time to time. A new controller proved to outside the budget at the time so with some coaching from other Isuzu owners he has installed a manual control system.
The solution was to connect controller (using the pin numbers on the controller connector) wires #5 (for the glow plug relay) and wire #13 (for the dash indicator light) through a momentary push button switch to ground. A convenient ground connection can be made to the controller ground which is wire #10.
The plugs are activated by pushing the button for a few seconds before engine crank. Longer is needed in colder weather, obviously shorter in warmer weather and should not be needed at all with warm engine. Always favor the shorter time as best possible to improve plug life, eventually experience, “operator training”, will help with proper timing.
The Elusive Fuel Screen Strikes Again:
Al and Marcia Glick aglicknmex(at) gmail.com
Al and Marcia had what appeared to be a fuel starvation problem at the very beginning of their return trip from Mexico. They had just purchased some fuel which also introduced the possibility of bad or contaminated fuel. The Trek would only travel a few miles then loose power. A waiting period would then allow it to travel another few miles then repeat.
The problem was soon traced to the aptly named “Elusive Fuel Screen” see Infoletter #35 Letter 35 – Northwest Trek Fun Club (nwtfc.com) This screen, that does not appear in any manual or maintenance instruction, was packed with debris to the point of near total blockage.
Editor note: At my initial inspection of this screen I found significant debris, much less in subsequent inspections, but still something. The only screen/filter prior to this in the system is the water separator.
Really Nice 1994 Makeover
Dave Mullally davidjmullally(at) gmail.com
Wrapping up our 4-year exterior makeover project.
Last year we vinyl wrapped over some of the original, badly faded and peeling decals.
This year we tinted the side windows.
Some before and after shots below showing progress from August 2020 until March 2024.
These things take time.
Breakdown in Davidson Saskatchewan Canada:
Heartwarming and a Tragedy
Eric and Michelle Raub eric.raub11(at) gmail.com
Editor’s note: I have included this story in it’s entirety. It is both a heartwarming example of people helping people (Trek Tracks included) followed by a true tragedy to good people.
I am going to paraphrase in an attempt to condense a long ordeal.
First Eric and Michelle experienced a broken left rear axle just outside of Davidson SK, Canada, a very remote area. They were there nearly 10 weeks to get it repaired. Below is their story and a letter
_________________________
I was there so long and they let me work off the books and stay in my trek in my shop. I became like part of the family there. I wrote the town and they won business of the year. This is what I wrote.
“Hello Davidson SK,
I am an American that travels between the lower 48 and Alaska in my 1992 Safari Trek (an oldie but a goodie) a couple times a year. Despite my best efforts to keep her running in top condition, this year I had a catastrophic failure and broke an axle. This is not an item that is readily available to purchase and being in the quaint town of Davidson (middle of nowhere Canada) made it even more difficult. It would have been hard even in America, but they did it! All of the employees of “The Highway Brothers” made me feel welcomed as part of their work family.
It started with a break down and two calls! I called the RV shop in town and was immediately referred to The Highway Brother’s NAPA shop. They came out right a way. They ensured that my health and well being was taken care of and that I was alright! (the tow part of their business) Thanks Tom!! They towed my RV to their shop and got to work on it right a way, trying to get me back on the road. We soon realized this was not going to be an easy task to do. They were quick with their ingenuity to find the right parts. Which took us across all of North America. They found the correct parts needed and worked smartly to have them delivered at an affordable price. Thanks Janna and Melissa! This took about 6 weeks to procure and deliver all of the right parts. Which I think is pretty good when it comes to finding parts for RV over 30 year old!!!
The team of mechanics Joe, Erik, Chase (Pretty Boy), and Brad did the outstanding job of putting my RV back into working order. They
installed parts, inspected work, test drove and ensured my RV was road ready, before letting me leave. All while in one of the busiest parts of the year for their staple of clientele (the people of Davidson and surrounding area). They worked on my RV while farmers brought in tons of farming equipment needed for planting and spraying, 18 wheelers so truckers could get goods delivered and they must be the only shop in town to do oil changes and replace tires!!! They do about 40 of these a day. Sorry Phil (the competition across the tracks). They also had great communication with their clients, farmers enjoyed talking to them while waiting, mother’s trust them with the recommendations for tires and they seem to go above and beyond what is expected of them. Service is top notch!!!
While taking on this endeavor of part’s procurement, installment and delivery of service, they brought me into the fold of their work family. They made sure I had a place to stay, showers and clean clothes, and food in my belly, (muffins from Janna which her husband and son isn’t allowed to have because they are for the shop, heard that from him, lol) They also made sure I was knowledgeable of the adventures that await Davidson citizens. They helped identify the Co-Op and eateries, the Hardware Shop and surrounding area to make sure I wasn’t going stir crazy while awaiting to get back on the road.
They invited me to a few cook outs, where I met about 10% of the town. I got to see a wonderful parade and activities for Canada Day (saw the other 90% of the town. The town put together, softball games, and car show. They notified me of the near by lakes, even went to a bar that broke a World Record, next town over. By the way who ended up with the goat?
All in all I couldn’t have been so lucky to break down in Davidson and been directed to contact The Highway Brother’s to get me taken care of so I could get back to my life. Joe and Tom Klassen run a phenomenal business, they treat employees life family and clients like friends!! They easily could have given me a quick fix and sent me down the road to the next shop, but they didn’t. They genuinely care about the work they do, the service they provide, and the wellness of their clients. They explained the whole plan and gave honest estimates and helped manage expectations of the work that needed to be done. Davidson is very lucky to have a business that represents them in such a fine manner. I have made friends for life and in the end I got to experience Canadian life for a few weeks eh!”
This is why I am recommending them for business of the year!!
Eric M. Raub
Satisfied Customer
Tom and Joe have been fantastic!!!
__________________________
Editor again: and then this tragedy occurred;
This is the family that took me in when I was stranded in Davidson SK Canada. Please help him out with the horrible tragedy stuck his family.
Water Heater Quick Drain:
Dana and Cheryl Luce danasluce(at) gmail.com
Editor’s Note: Dana has a 93 2400 with what looks like the standard Suburban Water Heater, however it appears as though some previous owner had drilled and tapped the large 1 1/16” nut that had the anode attached to and installed a ¼” drain plug. We are guessing this was done as the large nut is so badly rusted in place any attempt to remove it would risk the heater integrity. Dana replaced the plug as shown below.
I got tired of fighting with the drain plug on my water heater when winterizing my ‘93Trek. I replaced it with a Dernord 1/4 inch stainless mini ball valve NPT female x Male. This valve is available from Amazon, search for Dernord SUS316 and has a Temperature range of minus 30 degrees to 325 degrees. Temperatures here in Sisters OR go into the minus degree range at times during the winter so this works great for me.
“This message brought to you by my 10 magic thumbs!”
Dry Wood Termite Invasion:
I may be the only one in the country to have this one though. Watch out for dry wood termites if your rig never ends up in freezing weather. You pick them up Near the coasts in places where it doesn’t freeze. They are eating the inside of my cabinetry. I thought I had them but discovered they are all over the place and now I’m waiting for next winter to make sure to park in freezing weather for a couple of days with my heat off. I’m also treating the ones I can see, little holes coming out of my woodwork where they are shitting their sawdust out. If your rig has been in one of these places, and you see little piles of sawdust you can’t identify be careful.
Loose Alternator and Resultant Bad Wear
Bruce Matlack matlackwindsurfing(at) gmail.com
Bruce was having trouble keeping alternator belts from slipping, investigation revealed excessively worn holes on both the mounting bracket and the alternator alowing the alternator to shift and vibrate. He managed to get the Trek home from many many miles away by lashing it down with rope. It is believed all this wear is the result of a mechanic failing to tighten the “hinge” bolt after belt replacement which then allowed vibration and a huge amount of wear.
Remember the I-Trek Infoletter is created using content submitted by you people, the owners and users of these fantastic machines. In my opinion there is no better way to help the owners and users than to share between all of us. PLEASE feel free to submit anything that you believe might be helpful to other I-Trekkers to me at islandduo(at) comcast.net at any time and I will include it in the next infoletter.
FYI the Trek Gathering in Quartzsite Az. 2025 will be better than ever as it has been decided to extend the “official” dates of the gathering. It will be from January 16 thru 21 2025. There will new activities and more time to learn about your Trek and socialize as well. Remember these are the “official” dates as many will arrive early and many will stay late, some by weeks. Any questions feel free to e-mail me.
I apologize for the lateness of this issue.
Bret