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1970 Dj-5a Lhd Dispatcher 100 Ex-postal "rattletrap"

Discussion in 'Builds and Fabricators Forum' started by Rustman, Dec 31, 2019.

  1. Dec 31, 2019
    Rustman

    Rustman New Member

    Charles Town, WV
    Joined:
    Dec 28, 2019
    Messages:
    15
    When I was 17 and driving around my Dad's hand me down 84 Toyota pickup with rust holes you could put your head through I decided I wanted an old Jeep. I really can't remember the series of decisions that landed on Dad and I driving 3 hours to look at an old Postal Jeep in Philly. I wanted it but was terrified of the thing with the shaky front end and leaking master cylinder. My father, oddly being the braver man at the time, drove it home while I drove the family van following. At a stop at an I-95 rest area he also demonstrated in the parking lot two things (1) that the old Jeep can REALLY GO FAST and (2) that beside the other idiosyncrasies to be worked out the throttle would stick.

    When I bought her she had a black paint job and silver wheels. this was over the clown paint job of it's former life as a 'Water Ice' truck. Must be a Philadelphia thing. Everywhere else I go they just call it Italian or Shaved Ice. 'Water Ice' seems both redundant and pedantic... I drove it in black for a while and then decided to make her Rustoleum blue and stencil on "McHales Postal Service" and "USN". When I parked it I'd hang a life ring from the mirror. It brought a lot of attention at the car show and blue grass festival in Deale, MD that year.

    After bringing her home the next few months saw a new master cylinder, new wheel cylinders, new king pins and nylon bushings on the front axle and a host of other minor things. I drove her as a primary car for a couple of years and decided I wanted a 4x4 so I went back to my other roots and got an 84 Toyota pickup, 4x4 this time. But that's another story. The Jeep stayed around and in fact was used for parts runs for the pickup quite often.

    I then got married and the Jeep was used less and less, we were poor so it was parked with the insurance and registration dropped. And it was parked for fifteen years! This year I decided to resurrect the old girl. So two new (used) tires to replace the two worst on the Jeep so she would at least roll into the trailer was followed by some fresh gas, replacing the condenser points which had corroded into an art project and tearing the carb halfway apart to clean it enough to make things go. On November 30th 2019 Rattletrap moved under her own power! And left a murder scene in my driveway as I realized the transmission cooler lines are as porous as a screen door.

    I travel a lot for work so much of December nothing happened but ordering parts off the internet. But that's changing now. Pictures and more of the story in the next post.
     
  2. Dec 31, 2019
    Rustman

    Rustman New Member

    Charles Town, WV
    Joined:
    Dec 28, 2019
    Messages:
    15
    Classic 3/4 pose showing the layers of paint shedding off:
    Engine compartment with the GM 153 engine:
    Kaiser Jeep VIN tag. I refer to her as the "Last of the Kaisers" because somewhere around there things must have switched to AMC/AM General:
    I've been searching out the manuals when I started I never had the Service Manual, only a Universal Jeep CJ/DJ one, never the correct one for this model. The service manual was a recent eBay find and as a bonus the lubrication chart was with it as well. I believe the only manual I'm missing now is the Operators Manual.
     
  3. Jan 2, 2020
    Jeff Bromberger

    Jeff Bromberger Straight outta Bellevue! 2020 Sponsor 2019 Sponsor

    Dallas Metroplex...
    Joined:
    Jun 28, 2019
    Messages:
    86
    I have a bunch of new parts for a 10 inch brake solid axle, if you need. Bearings, that goofy tie rod end (LHD only) and a new kingpin kit. Also, new square U bolts in case you need to reinstall the Clark front axle.

    I have an odd feeling that maybe you already did a front axle swap...
     
  4. Jan 3, 2020
    Rustman

    Rustman New Member

    Charles Town, WV
    Joined:
    Dec 28, 2019
    Messages:
    15
    Jeff,

    Thanks for the offer. The Kingpins were redone when this was my daily driver. The axle is the original Rockwell, still a solid, still 2wd with Kingpins, but it's not a Clark, it's a round axle, not square. Not sure the brake size. Not sure about my tie rod end. The steering components were all ok enough for Maryland inspection all that time ago. But as I proceed I'll let you know.

    Thanks
     
  5. Jan 3, 2020
    ojgrsoi

    ojgrsoi Retired. 2020 Sponsor 2019 Sponsor

    Weatherford, TX
    Joined:
    Dec 30, 2002
    Messages:
    1,904
    FWIW

    DJ5A, B & C all came with 10" brakes.
    D, E, F & G all came with 11" brakes.
    L & M came with something else. :shrug:
     
  6. Jan 3, 2020
    Rustman

    Rustman New Member

    Charles Town, WV
    Joined:
    Dec 28, 2019
    Messages:
    15
    Mark thanks! I did the brakes almost 20 years ago. And I know they need work now as they don't work :D Ask me how I know :shock: (Pulling back into my drive after the inaugural test run I almost hit the horse trailer. Turns out the parking brake does still work...)

    Anyway I don't know yet what parts are needed. I'm figuring one of the lines rusted out somewhere. It's on the to-do list.
     
    Last edited: Jan 3, 2020
    ojgrsoi likes this.
  7. Jan 3, 2020
    Rustman

    Rustman New Member

    Charles Town, WV
    Joined:
    Dec 28, 2019
    Messages:
    15

    Here is the before and after pictures of my carburetor. In between I took it apart down to every component I could. Removed all the grease, carbon, dirt and varnished gas by soaking in a Crockpot with Pinesol. Rebuilt using a rebuild kit from Mike's Carburetors and some new Fillister head screws from Fastenal. Aluminum and linkages were painted with Alumi-Blast spray paint, multiple coats then baked in the oven for a few minutes at 200 degrees. I followed directions to the crossed t and dotted i. Upon reinstallation the carb performed flawlessly!! I pulled the choke, cranked her over, once the fuel pump had filled the bowl Rattletrap started right up. I eased off the choke, had to adjust the idle speed slightly to keep her running, but after that she was perfect. It was my first carburetor rebuild and I'm still amazed. So my advice if you've never done one before and are getting ready to is; simply follow directions, take lots of photos as you take it apart so you know how it goes back together and just be methodical.

    That was the morning of New Years's Eve. I'm still amazed at my success.
     
    Twin2, Dphillip and ojgrsoi like this.
  8. Jan 4, 2020
    Jeff Bromberger

    Jeff Bromberger Straight outta Bellevue! 2020 Sponsor 2019 Sponsor

    Dallas Metroplex...
    Joined:
    Jun 28, 2019
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    86
    Parts for the older 10 inch system are harder to get than the more current 11 inch system. If you need stuff that's not local to you, I've "got a guy" here in Texas, about an hour from my front door, who specializes only in DJ5 parts. :rofl:

    I just was forced to swap front axles because of a rare part that needed to be replaced and isn't manufactured any longer. In the process, I have the added perk of going up to the larger size. As I mention in my "regular" thread, I now own a 1974/1975/1976 DJ5 "half C, half D", all depending upon which part you're talking about!
     
    ojgrsoi likes this.
  9. Jan 7, 2020
    Rustman

    Rustman New Member

    Charles Town, WV
    Joined:
    Dec 28, 2019
    Messages:
    15
    Would your guy be John Rose? Apparently he worked for the Post Office as a fleet mechanic for a long time before making this his business. He certainly knows his stuff on the Postals.
     
    ojgrsoi likes this.
  10. Jan 7, 2020
    Jeff Bromberger

    Jeff Bromberger Straight outta Bellevue! 2020 Sponsor 2019 Sponsor

    Dallas Metroplex...
    Joined:
    Jun 28, 2019
    Messages:
    86
    Indeed. His back yard is a sorta graveyard for postals. He has everything there, except for that one tie rod end I was struggling to find.

    If you visit, and you should, be prepared to spend time. My first ended up at 3 hours, and we talk via phone every 3 or so weeks now.
     
    jeepstar and ojgrsoi like this.

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