That could be an exhaust leak, if it gets louder with rpm I would look for a leak around the manifolds and air injection pipes.

That's a nice looking truck - what we could see of it. An XLT with some personal history, would be worth fixing properly.
Most of your problems are minor, fairly simple fixes. Fuel mileage is way off - I got 100 miles on less than 1/2 a tank yesterday with an extended cab on a towbar hooked to the back. Might want to have yours looked at.

Guess who's got an update!!!

Me! 9 years later!

• replaced the broken mirror
• Replaced the driver's side window motor
• Replaced the wipers motor
• The rushing water was apparently by design. It was actually the water running off the cowl into the cowl drains on the side when I would take a turn
• Replaced the door covers
• Replaced the e brake cable, it had snapped off.
• Had to replace the front bumper after I was hit by my neighbor

Rear bumper still sags. Sadly I have a leak in both sides at the firewall. Pretty sure the passengers side is the windshield leaking because it's not at the firewall but dripping down at the dash.

On the driver's side, I think it's leaking at the PCM , I think the PCM gasket has rotted out.

Check the drip rails above the doors. You'll probably find the sealant in the channel has a long crack in it. That's probably the origin of your windshield leak.

Can that really chase a dashboard leak? Not disagreeing.. more shocked

Yes, like Duke5A said, that rain drip rail seam above the doors can cause some pretty goods leaks that are hard to find the source of. I recently had a 1992 F150 repainted. The guy at the paint shop that seam area is one of the most common sources of leaks on these old trucks.

The EEC seal can be replaced and most likely sourced on eBay. I may have a spare in you want it. I'll hafta look ...

Also you can stuff paper towels around and into suspect areas (in the interior) and then see in what areas the towels are wet after a rain, car wash, etc.

so a couple things in the last roughly 48 hours.

1. To Duke's suggestion, I climb up topside and scraped out the old seam sealer, it was cracked like nobody's business. Replaced with fresh 3M seam sealer. I went the entire length of the rails. But not between the roof and the A pillar? There was no sealer there so I'm assuming that's by design.

2. You guys will probably kill me but boy did I seam seal the everliving pi$$ out of the windshield. Originally I was going to replace the windshield clips all the way around, but when I saw that some of them, particularly the bottom ones were buried beneath the windshield and I'd have to remove it to get them out, I decided to just seal them shut. Hopefully my windshield never gets a crack. Pretty sure that was probably where it was leaking in because prior to me working on this there was barely any leak. Then I used a hose and compressed air to blast all of the gunk out. 1 day later, it's Niagara falls in the passenger side. So I just loaded in the sealer where there were gaps.

3. Next up is brand new window felts inner and outer and brand new door seals (the ones at go on the cab of the truck). Also got a brand new hood cowl seal which will also go on. Before all that though. I'm going to try pulling the EEC gasket. I already ordered one off eBay that looks like it's in somewhat better shape than the one I have. Door felts and hood cowl seal should go in next. Which brings me to bullet 4.

4. The dreaded door seals. So basically my rockers and screwed. Passengers side isn't terrible with rust. I checked the bottom and the rust only appears to be top side. I'm planning on grinding it down. The problem is, that the pinch... Seam.... The ridge that the door weatherstripping sits on rotted away entirely so the weatherstripping on the bottom is just flapping in the wind. I'd prefer not to have to weld in an entire new rocker so I'm going to see if there's anyway to get that seam in. As for the drivers side... Same issue, needs a new weatherstripping ridge. Yeah. Yeah, that's what I'll call it. However, it also needs a new... I forgot the name but where the b pillar meets the rocker, it's pretty much gone at the bottom. I watched one guy do a YouTube video of precisely what I need but he took off WAY more than I think I need to because he had straight holes through the floor.

Unfortunately for me, I am going to have to learn to weld myself... I have never done it before, but no shop nearby will even touch it. I actually was fully prepared to pay $6k for both sides. I didn't offer a number, but asked multiple shops and 4 said they wouldn't touch it. The last one hesitated, and when I said throw out a number, he reneged and wouldn't. So I'm going to be buying 1A panels and just seeing what I can do since nobody else is willing to work on it.

I wanted to wait until I had the entire water problem fixed but I don't think I will be able to fix the dampness at the rocker panel, because since theres no ridge for the weatherstripping to sit on, it just flaps into the wind. Since the weatherstripping is flapping in the wind, any dampness during rain just makes its way onto the rocker and makes it look like it's coming from the cab. There aren't any drip streaks from further up so I'm certain it's drifting up under the door. Not to mention while sitting in the cab, I can see light out from under the door.

Anyway so yea... In summary
1. Door window felts
2. Hood cowl seal
3. EEC gasket
4. Weld the ridges back on so I can reseat the weatherstripping.

If ya'll have any advice or videos on number 4. Let me know. Going with a flux core welder for $200 off Amazon. ArcCaptain I think it was called. Anything is better than letting the rust creep. And yes. I know I need to either remove the rust or cut it out entirely. If this goes well, then the truck bed wheel fenders are next.

I went to 5 shops in my nearby driving distance and not a single one would give me a quote for repair. I was silently prepared to pay $6,000 but didn't throw the number out first. Not a single shop would give a number, just told me to sell the truck. Whether they're too busy or not. I couldn't tell you.

I'm going to give it my best and I know it won't be good. Actually I'm sure it will be bad. It will be my first time welding which I'll be practicing on some scraps to get the settings right. But we'll see what happens. Anything will be better than what is there now. I'm handy enough to have built an addition on my house and have done my own dashboard swaps (I know, not body work but giving the impression that I can make myself handy).

I've been watching some youtube for some 8 months now trying to get myself ready for this. I know that I need to cut out all the rust (or at the very least grind away where it hasn't gone through.) Unfortunately I don't have a garage to cover this under so my plan is to take two days off work, tackle one side and get it to primed so that it's protected from any additional rain before going to the other side.

https://imgur.com/a/abdITaO

Anyway, like I said. Wish me luck. We'll see what happens. Open to any small slivers of advice worth sending my way

edit: other album links https://ibb.co/mX7vvp9 https://ibb.co/y4SvwGT https://ibb.co/mD3Xs4j https://ibb.co/p4N4nJS https://ibb.co/wK5xtjB https://ibb.co/WzdKKNR https://ibb.co/DMMVPdn https://ibb.co/rpjVg5t https://ibb.co/rGRF9DM https://ibb.co/NtqKZGm

Advice? Stop. Hear me out. I'm in a very similar position you've found yourself in. My '92 was my grandfather's and I've been working on it to make it into a fair weather driver I can toss the kids into it. The truck has a great deal of sentimental value to me and being from Michigan it is rusty. I knew it was going to need to work, and lot's of it. I ended up storing it for almost ten years as I didn't have the tools or a garage to work in to do it. I did light things like trimming out rust and dumping oil in spots to preserve it. Once I got established and had a place to work I started tearing into it....because when you do you're going to find more and more as you take it apart. The cab corners and rockers on my truck were in good condition as I had them replaced a long time ago, but the rest of the truck...I just started working on it last year and you can see the photos below.

Go over the entirety of the truck and pay close attention to the frame. You need to set a realistic limit and if that limit is hit then let it go. After going over everything I concluded it would need a bed, fenders and a core support. I scored the fenders and core support from Texas with absolutely no rust. Swapped it in and did a bit of suspension work. I've got about $800 in the front end. Over the winter I found a bed that was brought up from Florida and paid $900 for it. I'm guessing I'll have $4500 into everything by the time it's all said and done minus professional paint. The cab does need a bit of work and I'll be doing that myself as I have the tools now and experience now.

I would seriously wait until you have a place to work on it.


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Simple update...

Fixed the leak. Ended up replacing the EEC gasket, there is maybe a few drips coming in on the hood latch cable. Going to seal around it. Otherwise leak is done.

On the passengers side, I tried welding in a 90* elbow the length of the rocker. I made a mess of the welds since I haven't a clue what I'm doing but it's in and I didn't blow threw the bottom. Coated all the edges with seam sealer. Going to hit part of it with body filler just to clean up the way it looks, then I'll be hitting it with some touch up color match and calling it a day.

That being said, all this work later and the check engine light comes on...

142 - something something TPS so I ordered a new TPS.
172 - something something O2 so I ordered a new O2 sensor.

So I'll be swapping those out. Was wondering if there's any sense it swapping in a new IAC while I have the throttle body off. Any thoughts?

Otherwise, I'm taking a new route with the drivers side rocker and cab corner. since I really don't know what I'm doing welding. I'm planning on just using a patch panel adhesive epoxy. 3m makes it. As I said, the truck is not a daily driver and I just want to clean it up so I'm not worried about expansion lines if the adhesive shifts at a different rate than the body.

I also have a tach cluster inbound since my truck didn't have one. So that will be nice.

Anyway, haven't had much time to work on it for a while. Swapped out the door seals on the passenger side , haven't done the driver's side yet.

Need to tackle the driver's side seat belt bolt before anything else at this point.
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