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My 2001 2.4L service record

17267 Views 72 Replies 10 Participants Last post by  Cusser
5
I'll be using this thread as a service record for my truck.

I got a 2001 Frontier XE 4 cyl, 5sp MT with 143,930 miles for $1,900. It has a lot of leaks and a pretty major dent on the passenger side along with faded paint. If the truck were babied, I'm guessing I'd be able to sell it for at least $3,500 based on what I found on cartrader.

The goal is to fix the car up with my son, who's a senior in high school, and either give it to him or sell it and use any profit to go towards something a little nicer for him. I'll let him decide. In the mean time, this project will be a good learning experience for him. If he decides to keep it, I'll upgrade some things like tires and audio.

Fortunately, the truck has a timing chain, from what I saw online, so I don't have to worry about that. Former owner said she replaced the water pump and power steering pump.

Last weekend I got some used tires, as 3 of them were completely bald and were showing threads. They're not pretty, but at least it's safe to drive now. I also replaced the valve cover gasket as it was leaking heavily. That ran me another $40. I could have gotten it cheaper online, but I really needed to replace it soon because it was leaking so much oil. Also replaced the windshield wipers.

This morning, I replaced the interior driver door handle, because the locking lever was broken on the old one. I got this for $9 on eBay.

Currently, the truck needs:

- Possibly a new radiator. This one seems to be leaking along the top. I checked the cap and it seems to be fine. Will require more testing, but a new rad is only about $55.

- Power steering gear box is leaking. A new kit is around $40 or less. A reman one is $255. Not sure about used, but I'd like to learn how to rebuild this one. Also will require a flush with new AT fluid.

- the radio doesn't work. I found a JVC with bluetooth at Walmart for $60. I'll probably go for that.

- I can smell exhaust when I run the a/c or heater. Not sure where an exhaust leak would be coming from.

- Service Engine Soon light is on. Not sure if this is an oil change reminder or a check engine light. Could be related to the exhaust leak I smell in the cabin.

- Clean the engine with degreaser, top and bottom. It's coated with oil due to all the leaks. This will allow me to see if there are any other leaks.

- Belts look ok for now. I'll decide if it needs new ones when we remove the rad, but they aren't making any noise.

- I found an oily wet spot where the transmission and motor meet at the bottom. Not sure if this came from the valve cover gasket leak or if it's the main rear seal. If so, I'll have to remove the transmission. Fun. It might be smart to replace the clutch, but it could very well have another 25k miles on it, and if my son decides to sell it, I'd rather save myself the money in parts. Will also have to grease the clutch fork; it squeaks. We'll save this job for dead last.

- Coolant flush. The truck isn't overheating, but if he decides to keep it, we'll also change the thermostat and hoses.

- Transmission fluid change

- Change differential fluid

- Brake fluid flush

- New front brake disks and pads.

- Check the rear brake drums

- Pull and Bondo the dents and repaint the truck and wheels. I'm not a pro at painting and body work, but I have the equipment and can make the truck look more presentable.

- Air filter

- check cabin filter

- Change the oil and filter

- Clutch start switch isn't being pushed in by the pedal. Needs some kind of padding where the rubber pusher used to be.

- All wheel alignment, if he decides to keep it.

- Spark plug cables look new. Have to inspect spark plugs.

I think that's it. Once these things are fixed up, this truck will run smoothly and look much better. It'll be a great experience with my boy. Hopefully I can make a little profit off it, too.



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The JB Weld was a fail. It's still leaking. Looks like I'm going to have to replace the radiator. No biggie. Glad I didn't flush the radiator with fresh coolant. Probably gonna replace the thermostat while I'm at it.
144,194 miles. New aftermarket radiator, thermostat, and rad cap that I got off Amazon for $55 total. Truck is running well.

Getting the damn thermostat on was a PITA. It kept slipping down when I'd install the housing causing a leak. Ended up having to remove the power steering bracket entirely to have easier access, then put a bunch of black gasket maker on the edge of the thermostat to hold it in place. My son and I let the gasket maker get tacky for 20 minutes before installing the housing. No more leaks.

My son wanted to see how a thermostat worked so we did the boiling test. It was my first time testing one too, so it was cool... Or hot, heh heh.

Flushed the cooling system 5 times with distilled water, then added a gallon of Prestone coolant between the system and the reservoir and finished it off with more distilled water. That should be around a 50/50 ratio.

Also replaced a few rubber vacuum lines underneath the air filter housing since they were embrittled.

Checked the belts and they were fine. Coolant hoses looked good too.

My son was frustrated at the thermostat leaks because we'd have to take everything apart again. I told him how we're lucky that we don't NEED the car today and how when I was on my own I'd run into these problems and needed the car fixed that day. Otherwise, I wouldn't be able to get to class and work and couldn't afford to take taxis to get around nor a mechanic. His attitude changed for the better. Life is good, and I'm grateful my kids have a better life than I did at their age.
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Any pcv removal and replacement tips you could offer. Gonna have to change mines out soon
Don't tug on the hose too hard if it's old. Or better yet,be ready to possibly replace it. Have a flashlight handy because of the nooks and crannies.

It's going to take a lot of patience.
144,582 checked for a cabin filter. Mine doesn't have a slot for one. I'd have to cut the slot where it's marked. I'm just going to leave it.

On a good note, the exhaust smell in the cabin has stopped entirely. One of the things I fixed seems to have fixed that problem.
144,632 finally got around to changing out the transmission fluid. Used some GL4 stuff off Amazon.

While under the truck I noticed a few coolant drops. Hopefully nothing serious. Topped it off and for now I'm just going to keep an eye on it.

Checked the clutch and brake fluid. Brakes needed a little topping off but clutch fluid was filthy again, same color as before. Probably residue that was in the line. Gonna flush that out again next week, and going to keep flushing regularly until it's not that color anymore.

Power steering topped off due to leak in the gear box.
Found the source of the coolant leak: a hose that's right above the PCV valve. I'll tackle it next week.
144,884 replaced the leaky hose as well as another hose right behind it. Not sure which was leaking so I just replaced both. One was molded in a U shape, and the other went to the heater core out of the thermostat housing. I recommend getting an 11 inch, 45 degree bent needle nose pliers to replace those hoses. It couldn't be done by hand. The power steering pump and bracket, tire, and oil filter will also need to be moved out of the way for better access.

Oddly, when the coolant was leaking out, the temperature needle stayed in the normal zone, but the AC stopped blowing cold. Once I replaced the hoses and refilled with new coolant, the AC blew cold again. Gonna do some research to see if the coolant level has anything to do with the condenser keeping cool. Not sure how it would be considering it doesn't plug into the radiator.
Got a full suspension kit this past weekend. My son and I replaced upper and lower ball joints, all 4 shocks, stabilizer bar links, tie rods and center link, and the idler arm. Greased all ball joints.

Notes: Shelved the old idler arm and stabilizer bar links since they looked good. The OEM lower ball joint uses a clip that's covered by a rubber seal; in order to remove the seal, I had to slightly press out the ball joint then press it back in; this lifted the seal so I could get a flathead under it and pry it out.
Took it in for an alignment yesterday. Got it aligned but the steering wheel isn't straight because I'm off by a tooth with the pitman arm. Damn it. The alignment has a 6 month warranty so we're going to hold off a few weeks to adjust it, then take it back to get it realigned.

I still don't like how the steering feels. I feel a random drift in either direction sometimes and a bit of play in the steering. I wonder if the toe isn't facing in enough. I'm going to ask that they look into that.
Replaced the fuel pump yesterday morning along with all breather and fuel hoses coming out of the tank and at the fuel filter along with the fittings at the filter. Filter was replaced a few months back.

*Replaced the leaking seal in the steering gear box some time back. Unsure of miles at the time; estimate around 147k.
About 150k miles. Changed the oil and filter.

Tried straightening the steering wheel but the pitman arm and steering column splines are all slotted in a way that you can't make small adjustments. That means the alignment is where the adjustments to the steering wheel, with respect to the wheels, must be made. I'm going to take the truck back to the shop and have them look at it.
155,500 replaced the 2 coolant lines under the air filter. 1 of them was leaking. Used generic molded lines from AutoZone and PepBoys and cut to fit.

Up for an oil change. When the weather is better.
155,540 Supertech oil (5w30) and filter (ST6607).
Flushed clutch fluid with Supertech DOT3.

It's been 1 year and 11,000 miles since we got the truck, and my son has become very attached to it. He's currently in USMC boot camp. He went against my request to join the Army. He said he just wanted to be a Marine like his old man; I had to smile at that. Anyway, the truck will be in tip top condition when he returns. If he gets stationed stateside, he can drive it to his duty station. If overseas, I'll just park it in the back yard until he returns.

Except for the seal at the crank shaft pulley, there are no more leaks on the truck. Steering is still not as good as I'd like, but it's good enough. If I hold onto the truck, I think over time I'm going to replace all ball joints and steering components again but with quality parts. I used cheap parts off eBay to get it on the road.
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FrontyCB00

Nice project for you and your son. Good dad award. Also, thank you and your son for your service.

I'll be following along with your progress. I just bought an 02 XE King Cab 4cyl MT. After the initial tune up from my trusty mechanic, my plan is to teach myself how to maintain and repair and do as much as I possibly can by myself. I'm pretty handy with a wrench--I'm a yacht captain and am the ship's de facto engineer, but I've always driven newer cars until this one. Bought me a beater in order to achieve some financial objectives, including becoming debt free.

Have you picked up the repair manual for your truck? I found them here - https://manuals.co/workshop. The guy asks for a minimum donation of 5 GBP (the exchange rate is an unbelievable 1.3 at the moment). Not bad for a 3500 page repair manual.
FrontyCB00

Nice project for you and your son. Good dad award. Also, thank you and your son for your service.

I'll be following along with your progress. I just bought an 02 XE King Cab 4cyl MT. After the initial tune up from my trusty mechanic, my plan is to teach myself how to maintain and repair and do as much as I possibly can by myself. I'm pretty handy with a wrench--I'm a yacht captain and am the ship's de facto engineer, but I've always driven newer cars until this one. Bought me a beater in order to achieve some financial objectives, including becoming debt free.

Have you picked up the repair manual for your truck? I found them here - https://manuals.co/workshop. The guy asks for a minimum donation of 5 GBP (the exchange rate is an unbelievable 1.3 at the moment). Not bad for a 3500 page repair manual.
No, I haven't gotten the manual yet. Thanks for the link.

I'm all for debt free, man. Good luck! I'm trying to FIRE through rental properties. If you've not heard of FIRE, check out reddit's Financially Independent Retire Early thread. I hope my Service Record thread helps you. Feel free to ask me any questions via PM. I'm not a pro mechanic, but I've learned quite a bit over the years.
Currently around 156500 miles. The fuel gauge recently started messing up, reading inaccurately. It moves slowly up and down randomly, and spends most of it's time on Low Fuel. I pulled over when I first noticed it and there are no fuel leaks. We changed the fuel pump (which reads the fuel level) some months back and the pump still works. I'm going to leave it alone and use the trip meter to determine fuel level.

I drove around with a container of fuel to test the mileage limit. I got up to 289.7 miles and decided to fill up the tank, which took 13.5 gallons to fill up. Google said the XE takes 15.9 gallons, but I'm not going to risk the car shutting off on a busy highway, even if I'm carrying spare fuel. It can reach at least 290 miles and that's good enough information.

So to summarize:

290+ miles to a tank
13.5 gallons yielded 290 miles.
Recommend filling up by 240 miles at the latest.
Also, my son graduated boot camp last month and is an official Devil Dog. Oorah. I have the truck while he's in combat training. In a few weeks he'll be at his MOS school. I'm going to redo the entire front end suspension system again, this time with MOOG ball joints and quality shocks. It should be ready when he gets to his MOS school, at which point I'll load up my motorcycle, drive it up to him, and ride back home.
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Just ordered all MOOG parts: upper control arms with ball joints, center link, lower ball joints, tie rod assemblies, and front KYB shocks. The rear are Monroe shocks and fairly new; I'll see how the whole truck feels when the new ones are in place. I'd like a little bit stiffer ride. Currently the XE feels like a boat.

My son is in Missouri for training for a few months. My other son, who will probably inherit this truck in a couple of years when he's old enough to drive, is going to help me install everything.

Also, reminder to check the rear bearings. I'm getting a weird clacking back there randomly. It could be something needs tightening too.
159,525

Installed all parts listed above. The front shocks feel nice and firm. I think I'm going to do the back as well. Got lifetime alignment and Destination tires at Firestone.

Clutch slave cylinder has a small leak. Gonna buy a Luk cylinder eventually. It can wait for now.
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