The Restoration Process

The Parts List

I've kept a list of all the parts I've needed to replace on the beast, and I've tabulated the part numbers. Where there is an asterisk, there are several choices listed in the manual and my setup is the part number I went by. The fuel tank selector valve is one designed for laarger lines, but there is a smaller-line model available. There is also a switch in JC Whitney that would allow me to use the fuel tank guage selector switch as the valve control (part# 81DH2686W $34.95) switch. Update to that: While in West Marine yesterday, I saw a valve identical to the original for $17.
I found some tires and wheels on sale at a local 4x4 store (Offroad Performance). Tires are Dunlop Rover AT for $94 each, and white 15"x8" white wagon wheels for $32.95/wheel. I also picked up a Rancho RS 5000 steering stabilizer (Part # 5402) and shocks.
The retail prices are what is listed on the NAPA reciepts as being the full retail price. Most of the items rung up about %20 less than that price. I also had the radiator re-cored for $175 which needs to be added in. I bought the locking front hubs from Kent Grasso since the bearings in mine were shot, but I wanted to retain the original look. I replaced any questionable bolt/nut with grade-8 material everywhere. The threaded rod that connects the clutch pedal to the linkage is grade-7. I had to get a used bellhousing from Anything Scout and it cost ~$90. Both fuel tanks have rusted through and may have to be replaced. I'm checking on prices for them right now. -->Update: patched the passenger side tank with Grey Marine Tex. It's holding so far. A friend was able to weld new mounts to the driver's side tank. I replaced the lines (that run from the top of the tank, underneath, and then out of the tank compartment) with universal brake/fuel line which had flares and fittings already installed. The 40" was the size I chose since the originals were 38". If I'd had a flaring tool, I'd have cut it to the exact length, but it works just fine with the extra bends in it to take up the slack.
The heater core has a couple of pinholes, as well as a crack at the base of the bottom nozzle. A new one is being ordered. Update: Recieved the new one -> Stant Part # 9409, no NAPA or other parts source cross-ref. Price: $70 (ouch!).
The front driveshaft had an atrocious amount of play between the splines on the shaft and the slip-yoke it mates to. Howard Pletcher managed to find a shaft/yoke of the appropriate length, and is sending it to me as of 6/10/97. Update: Got the driveshaft from Howard ($56), and it scares me to see how much slop was in the old unit compared to the new one. It was a stranding waiting to happen. Thanks, Howard!!
All the original peices that I took off were stripped with a wire-brush, etc. and primed and painted their original colors. I'll still need to do some body work and replace the floorpans up front, but this is the list so far. -->Update: created some new floorpans from galvanized steel sheet until I decide whether to buy new floorpans at $60/each. The metal in front of the rear wheel wells had become non-existent (as well as part of the compartment that houses the gas tank. I replaced the metal with in the tank compartment with galvanaized sheet, and riveted perferated aluminum sheet in place to the body outer panels in front of the rear wheels. This gave the body filler a good surface to mate to and the repair is seamless and strong.
The latest in discoveries of hard to find parts is the accelerator pump cam on the carb. It is plastic and the little arm broke off the main bulk of the cam. I managed to epoxy the two pieces together, then make a wrap of fiberglass cloth/resin around that. It seems pretty secure, but I'm going to use the old broken cam that came on the 196 originally and fab a new arm for it so I have a spare. Holley doesn't make them any more, and I don't feel like buying a new carb for a tiny piece like that. I have some fiberglass sheet/plate (from my R/C car days) that's about 1/16th" thick. I've got a hole drilled into it that allows a tight fit onto the shoulder of the cam, and I an going to try to make the arm a two piece swandwich unit so that I can slide the pieces along the same axis to give more or less throw to the cam. I'll put plans up if I can think to remember them. --> Update: Fixing the original didn't last long, so I used the 1/16" fiberglass board, cut out three pieces and epoxied them together in a shape that resembles the original planshape. I drilled the three and put a machine screw through all of them to keep them snugly together. Drilling the hole for the shaft on the carb makes it perfect. Highly recommended to carry a spare like this!!
I've been trying to find a rebuild kit for my carb (stamped '3993' on the fuel bowl just above the IH number), and all the parts stores told me that they were on backorder from the factory. Advance got 3 different kits, but two of the kits had the accel pump for the R2494 Holley carb (one was part #5184), and the other looked like it was for a dual float bowl carb. An email to Holley supports their claims. Holley did give me the number to a place called Daytona Parts Co.@ 904 427-7108. They were able to sell me a kit (which requires a special accel pump they have to build) for $45 + $3.20 for 3-day shipping. I'll put the part number here when I find the packaging. They apparently have a huge book that tells which engine used which carb because the gal I spoke to x-reffed my engine to find that the model carb that was used was a R3993. --> Update: Ebay can be a good thing, indeed. I saw a blurb on the IH Digest that a carb was up for auction. I managed to win it (although it was about $20 more than I wanted to spend). The NOS carb works great!!
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Mail me if you catch any mistakes, please!

-- Engine: 152ci 4-cyl, T13 3-spd trans --

Part Description
Intn'l Part #
NAPA Part #
Navistar #
Retail $$$

radiator inlet hose 899 348 R1 Flex-Hose 15.43

radiator outlet hose 267 358 C11 7183 17.40

water pipe assy 151 245 R91 151 245 R91 24.79

water pipe o-ring seal 356 005 R1 NAPA Match 1.00

pump to thermostat hose 860 439 R2 7527 NBH 17.55

crankcase ventilator gasket 151 794 R1 N/A (Used blue RTV)

oil level dipstick 234 918 R11 N/A (Welded it together)

tappet/valley cover gasket 860 509 R1 N/A (Used blue RTV)

x2, core plug, intake manifold

x3, core plug, side of block

x2, core plug, Front/rear block 219-2057 .98

vacuum control 1 116 142 VC140 54.29

Condensor 1 932 004 RR175 5.61

Alternator 13-4003 74.35

Voltage Regulator VR138 15.46

Voltage Regulator (v8?) VR142 14.63

Distributor Cap FA86 20.68

Rotor Button FA85 5.98

Alternator Main belt 967 907 R21* 25-14603 18.60

Water pump 270 918 C92 W-137 41.30

Radiator Cap 703-2444 4.44

Spark Plugs Champion RJ12YC 3.43

Oil Pan Gasket 151 067 R2 OS-30765 10.96

Rear Mail Seal 273 587 C91 JV 724 44.14

Piston Rings ? ? J.C.Whitney also ?

Piston 334 218 C2 224-1686 STD ?

Rod bearing 273 587 C91 2800AP 19.26

Clutch Throwout Bearing 860 057 R31 IA 2005-C 82.39

Clutch disk 860 072 R91 R-5221 49.90

Clutch Pressure Plate 102 316 HF * CA-5321 56.15

Flywheel Pilot Bearing ST 527 BR7109 27.22

Valve Cover Gasket 151 193 R3 VS-38410-X 8.69

Intake manifold gasket 151 224 R2 * MS15082X 4.56

Exhaust manifold gasket 216 533 R2 MS15094-X 8.69

Head Gasket 151 454 R3 3175 32.95

Oil Filter 918 266 R91 1452 11.82

Ground Strap 57 038 R2 * 711284 10.38

Oil Pressure Sending Unit 259 357 C91* OP6622

Motor Mount Kit 941 919 R91 22109 35.28

Transmission Mount Kit 860 520 R91 23101 32.20

Rubber xfer case bump stop from above kit 941 918 R91 941 918 R91 3.05

- Rear Axle: Dana 44 open-diff -

Part Description
Intn'l Part #
NAPA Part #
Navistar #
Retail $$$

axle housing cover gasket 280 216 C1 P27768T

x2, grease seal rear axle 142 331 HA

x2, diff side gear thrust washer 127 889 R1 N/A (Wet-sand w/crocus cloth/WD-40)

x2, diff case bearing race 128 237 R1 25523 12.53

x2, diff case bearing 130 504 H 25577 24.39

pinion rear bearing 128 241 R91 31594 25.63

pinion rear bearing race 128 242 R1 31520 17.08

pinion rear bearing shim *no part #* N/A (Spares from local 4X4 Shop)

pinion front bearing shim *no part #* N/A (Spares from local 4X4 Shop)

pinion front bearing race 451 495 R1 02820 9.05

pinion front bearing 128 239 R91 02872 21.33

oil slinger 127 908 R1 N/A (Wet-sand w/crocus cloth/WD-40)

pinion bearing oil seal 352 477 C91 49161 11.51

diff pinion gear thrust washer 127 890 R1 N/A (Wet-sand w/crocus cloth/WD-40)

x2, rear axle shaft bearing race 13 201 D 3320 20.38

x2, rear axle shaft bearing ST 757 3382T 54.52

x2, rear axle shaft oil seal 127 979 R91 46047 15.28

x2, rear hub dust seal 128 234 R91 46044 7.79

----- Steering Parts -----

Part Description
Intn'l Part #
NAPA Part #
Retail $$$

Felt Dust Shields for drag link 66 644 H N/A

Drag link tension spring 1 057 YA N/A

Fuel Tank Selector Valve 103 386 R91 WH 6749 44.39

-- Front Axle: Dana 27 open-diff --

Part Description
Intn'l Part #
NAPA Part #
Navistar #
Retail $$$

Diff cover gasket 266 614 C1 P27603 4.87

x2, grease seal, front axle 250 646 C91 47430 5.43

x2, diff side thrust washer 220 151 R1 N/A (Wet-sand w/crocus cloth/WD-40)

x2, diff bearing race 869 627 R1 LM501311 17.71

x2, diff case bearing 663 557 R91 LM501349 15.52

pinion front drive bearing 871 244 R91 HM88649 20.70

pinion front drive race 871 245 R1 HM88610 9.82

pinion rear race 451 495 R1 02820 9.05

pinion rear bearing 128 239 R91 02872 21.33

drive pinion oil slinger 220 141 R1 N/A

drive pinion oil seal 127 968 R91 49161 11.51

x2, spider thrust washer 153 782 R11 N/A

x2, oil seal with ring 153 782 R11 5.5"OD x 4.5"ID x .125 cut from rubber mat

x2, felt oil seal 153 785 R1 153 785 R1 2.66

kingpin upper bushing 250 382 C1 N/A (Wet-sand w/crocus cloth/WD-40)

x2, Diff housing oil seal IPC 17036 49447 9.81

x2, Front hub bearing 663 557 R91 Advance Auto (Bearing and Race packaged together)

x2, Spindle bearing race 663 558 R91 # A-35 (bearing/race) 16.57

Hub Stud Autozone # 98136 .99

Lug Nut Autozone # 97819 .79

----- Brake Parts 10" front, 11" rear -----

Part Description
Intn'l Part #
NAPA Part #
Retail $$$

master cylinder 347 681 C92 36348 246.50

left front wheel cylinder 250 733 C91 37230 58.31

right front wheel cylinder 250 734 C91 37231 58.31

left rear wheel cylinder 352 786 C91 17507 35.46

right rear wheel cylinder 352 787 C91 17508 35.46

front brake shoes 386 277 C91 B-326 18.00

rear brake shoes 352 785 C91 TS-55 26.00

x2, Rear Brake selfadjust cable 308 147 C91 80811 4.23

Brake hold down pin, front 127 789 R1 80888 .68

Brake hold down spring, front 899 896 R1 80715 .79

Brake hold down pin, rear 127 789 R1 80705 .65

Brake hold down spring, rear 899 896 R1 80219 1.02

Brake hold down cup, rear 1 032 Y 80893 .93

Parking Brake Cable 331 737 C91 N/A

Brake shoe return springs, front (pair) 80301 6.00

Brake hose flexible line, rear 860736R92 LtLineofLa 16.50

Brake piping Tee-block, rear 127492R1 LtLineofLa 4.65

x2, Brake hard line piping (rear, 30") 813-1205 2.99

----- Misc Parts -----

Part Description
Intn'l Part #
NAPA Part #
Retail $$$

Fuel filter 967 640 R21 3943 5.91

Horn 85 132 R92 730-1054 18.18

Wiper Arm 60-750 24.59

Wiper Blade (Refills N/A) 60-011-1 6.49

Bulb, brake light 9 417 867 1157 .50

Bulb, reverse light 142 450 1156 .50

Signal Flasher 899 858 R91* 537 5.78

Muffler 22281

Exh Pipe hanger 35600

Exh Pipe Ring (OEM-Type) F7269

Exh Pipe Ring (Adv.Auto) 60203 3.99

Muffler Clamp 5/16"x1-3/4" 732-1030

Muffler Clamp 5/16"x2" (x2) 732-1034

Pipe adapter 1-3/4" to 2"

Angled Tail Pipe ~12"

Flared Brake Line 813-1223 2.98

Starter Solenoid Switch SS304 9.95

Gasket sheet kit (Carquest) JV-1 6.95

Moroso Exhaust Header Wrap (didn't work out) 47.95

Choke Cable assembly 293600C91 LtLineofLa 19.20

#4 Ga. Negative battery Cable 781126 4.20

Remote solenoid ST 81 14.95

Battery->Solenoid cable ~24"

Solenoid->starter cable ~36"

-- Engine: 152ci 4-cyl, T13 3-spd trans --
Part Description	Intn'l Part #	NAPA Part #	Navistar #	Retail $$$
radiator inlet hose	899 348 R1	Flex-Hose		15.43
radiator outlet hose	267 358 C11	7183		17.40
water pipe assy	151 245 R91		151 245 R91	24.79
water pipe o-ring seal	356 005 R1	NAPA Match		1.00
pump to thermostat hose	860 439 R2	7527 NBH		17.55
crankcase ventilator gasket	151 794 R1	N/A	(Used blue RTV)
oil level dipstick	234 918 R11	N/A	(Welded it together)
tappet/valley cover gasket	860 509 R1	N/A	(Used blue RTV)
x2, core plug, intake manifold
x3, core plug, side of block
x2, core plug, Front/rear block	219-2057			.98
vacuum control	1 116 142	VC140		54.29
Condensor	1 932 004	RR175		5.61
Alternator		13-4003		74.35
Voltage Regulator		VR138		15.46
Voltage Regulator (v8?)		VR142		14.63
Distributor Cap		FA86		20.68
Rotor Button		FA85		5.98
Alternator Main belt	967 907 R21*	25-14603		18.60
Water pump	270 918 C92	W-137		41.30
Radiator Cap		703-2444		4.44
Spark Plugs		Champion RJ12YC		3.43
Oil Pan Gasket	151 067 R2	OS-30765		10.96
Rear Mail Seal	273 587 C91	JV 724		44.14
Piston Rings	?	?	J.C.Whitney also	?
Piston	334 218 C2	224-1686 STD		?
Rod bearing	273 587 C91	2800AP		19.26
Clutch Throwout Bearing	860 057 R31	IA 2005-C		82.39
Clutch disk	860 072 R91	R-5221		49.90
Clutch Pressure Plate	102 316 HF *	CA-5321		56.15
Flywheel Pilot Bearing	ST 527	BR7109		27.22
Valve Cover Gasket	151 193 R3	VS-38410-X		8.69
Intake manifold gasket	151 224 R2 *	MS15082X		4.56
Exhaust manifold gasket	216 533 R2	MS15094-X		8.69
Head Gasket	151 454 R3	3175		32.95
Oil Filter	918 266 R91	1452		11.82
Ground Strap	57 038 R2 *	711284		10.38
Oil Pressure Sending Unit	259 357 C91*	OP6622
Motor Mount Kit	941 919 R91		22109	35.28
Transmission Mount Kit	860 520 R91		23101	32.20
Rubber xfer case bump stop from above kit	941 918 R91		941 918 R91	3.05

- Rear Axle: Dana 44 open-diff -
Part Description	Intn'l Part #	NAPA Part #	Navistar #	Retail $$$
axle housing cover gasket	280 216 C1	P27768T
x2, grease seal	rear axle	142 331 HA
x2, diff side gear thrust washer	127 889 R1	N/A	(Wet-sand w/crocus cloth/WD-40)
x2, diff case bearing race	128 237 R1	25523		12.53
x2, diff case bearing	130 504 H	25577		24.39
pinion rear bearing	128 241 R91	31594		25.63
pinion rear bearing race	128 242 R1	31520		17.08
pinion rear bearing shim	no part #	N/A	(Spares from local 4X4 Shop)
pinion front bearing shim	no part #	N/A	(Spares from local 4X4 Shop)
pinion front bearing race	451 495 R1	02820		9.05
pinion front bearing	128 239 R91	02872		21.33
oil slinger	127 908 R1	N/A	(Wet-sand w/crocus cloth/WD-40)
pinion bearing oil seal	352 477 C91	49161		11.51
diff pinion gear thrust washer	127 890 R1	N/A	(Wet-sand w/crocus cloth/WD-40)
x2, rear axle shaft bearing race	13 201 D	3320		20.38
x2, rear axle shaft bearing	ST 757	3382T		54.52
x2, rear axle shaft oil seal	127 979 R91	46047		15.28
x2, rear hub dust seal	128 234 R91	46044		7.79

----- Steering Parts -----
Part Description	Intn'l Part #	NAPA Part #	Retail $$$
Felt Dust Shields for drag link	66 644 H	N/A
Drag link tension spring	1 057 YA	N/A
Fuel Tank Selector Valve	103 386 R91	WH 6749	44.39

-- Front Axle: Dana 27 open-diff --
Part Description	Intn'l Part #	NAPA Part #	Navistar #	Retail $$$
Diff cover gasket	266 614 C1	P27603		4.87
x2, grease seal, front axle	250 646 C91	47430		5.43
x2, diff side thrust washer	220 151 R1	N/A	(Wet-sand w/crocus cloth/WD-40)
x2, diff bearing race	869 627 R1	LM501311		17.71
x2, diff case bearing	663 557 R91	LM501349		15.52
pinion front drive bearing	871 244 R91	HM88649		20.70
pinion front drive race	871 245 R1	HM88610		9.82
pinion rear race	451 495 R1	02820		9.05
pinion rear bearing	128 239 R91	02872		21.33
drive pinion oil slinger	220 141 R1	N/A
drive pinion oil seal	127 968 R91	49161		11.51
x2, spider thrust washer	153 782 R11	N/A
x2, oil seal with ring	153 782 R11	5.5"OD x 4.5"ID x .125	cut from rubber mat
x2, felt oil seal	153 785 R1		153 785 R1	2.66
kingpin upper bushing	250 382 C1	N/A	(Wet-sand w/crocus cloth/WD-40)
x2, Diff housing oil seal	IPC 17036	49447		9.81
x2, Front hub bearing	663 557 R91	Advance Auto	(Bearing and Race packaged together)
x2, Spindle bearing race	663 558 R91	# A-35 (bearing/race)		16.57
Hub Stud		Autozone # 98136		.99
Lug Nut		Autozone # 97819		.79

----- Misc Parts -----
Part Description	Intn'l Part #	NAPA Part #	Retail $$$
Fuel filter	967 640 R21	3943	5.91
Horn	85 132 R92	730-1054	18.18
Wiper Arm		60-750	24.59
Wiper Blade	(Refills N/A)	60-011-1	6.49
Bulb, brake light	9 417 867	1157	.50
Bulb, reverse light	142 450	1156	.50
Signal Flasher	899 858 R91*	537	5.78
Muffler		22281
Exh Pipe hanger		35600
Exh Pipe Ring (OEM-Type)		F7269
Exh Pipe Ring (Adv.Auto)		60203	3.99
Muffler Clamp 5/16"x1-3/4"		732-1030
Muffler Clamp 5/16"x2" (x2)		732-1034
Pipe adapter 1-3/4" to 2"
Angled Tail Pipe ~12"
Flared Brake Line		813-1223	2.98
Starter Solenoid Switch		SS304	9.95
Gasket sheet kit (Carquest)		JV-1	6.95
Moroso Exhaust Header Wrap (didn't work out)			47.95
Choke Cable assembly	293600C91	LtLineofLa	19.20
#4 Ga. Negative battery Cable		781126	4.20
Remote solenoid		ST 81	14.95
Battery->Solenoid cable ~24"
Solenoid->starter cable ~36"