Long story short: my family's had this Pathfinder (1998 5-speed Chilkoot edition, 350k) since new and I learned to drive in it. I've been driving it for the last couple years after I moved back west and recently decided to keep it indefinitely. Can’t find anything I like better! Work done up to this point:
Replaced P and D valve cover gaskets — man the driver's side is a pain
Replaced distributor due to persistent stalling at idle and eventual stall and refusal to start
Parked in the garage at the moment halfway through installing:
OME MD front springs
KYB Excel-G struts with new strut bearings, insulators, and boots
SFCreations 1" front spacer
LR 9447 rear springs
Bilstein 5100 (33-185552) shocks
ProComp Series 51 15x8 wheels (with current 31" Wranglers for now)
new ball joints, tie rod ends, sway bar links, lower control arms, trailing arms
missing link (as soon as I find something I don't have to buy 10 feet of!)
At this point new struts are assembled and old parts are off with exception of right lower control arm. Compressing the OME springs was a little tricky but using a third spring compressor helped I think. Pictures attached are before - lots of wheeling before but sadly no pics - and one of the (tight!) workspace as well as the rust above front fender. Plenty of rust on all four quarter panels, both rockers, hatch, and most worryingly roof adjacent to upper windscreen seal.
Only issue so far is with removal of P side lower control arm. Seems like dust and dirt collects above the rear bushing bolts. Removal was exceedingly difficult despite copious PB blaster and on inspection bolts are a little galled; suspect the internal thread is similar so I guess I'll chase the internal threads and dress the bolt and hope the driver's side isn't the same. Anyone have any ideas on how to prevent the same issue on the D side?
My major concern was rust and rot underneath. So far everything looks pretty good so next steps will be removing side steps, replacing fenders and rockers and doing something about the rust on the leading edge of the roof. I'd like to find a swing-away spare tire rack as well.
Comments always welcome!