Piffs Rebuild

Hub puller from harbor freight works great, ended up using it to pull emergency drum which I have to do again... (you do have to buy larger bolts for it)



Every thing in and installed correctly.
Installing wiper, made slight indentation with deadblow and flat head (not the best) then took dremel and sanded some parts down

measured and cut down shaft

I tested wiper and got adjusted, I don't have picture at the moment

got my new headlight switch installed too, (its a napa switch so I took dremel and ground down two sides so it fits the hole in dash)
everything lights up how its supposed to (got to get a picture at night)


I talked to the transmission shop and why the jeep pops out of reverse and first gear is my shifter rail on left side is broken, I still have to pull it apart and see what can be done. The trans shop said he would see what pieces he could find (letting me do the work so he doesn't have to charge)


My friend had me go test out jeep, he always seems to get me to stall my jeep every time, I threw it in low and I guess something cleared in my carberauter because I had allot more power.



Here's the part that ruins one weekend... I installed my drag link repair kit. Decided to take jeep for spin to test (so glad I wasn't in town that day)
Anyways as most of us know you do not drive with your hood not latched... the one time I don't check



I was going down the road what I believe was 55 -60 (My speedo cable keeps snapping) see my hood lift a little and by the time one can really do anything it hit the windshield and flew up. Lost my rear view mirror, never did find it. I'm glad I got a full cage because the cage stopped the frame from going to far back. Also I took off my emblems before this happened so they are unharmed. (the jeep was allot better for driving the straight a ways at least)


Now that I get a two week vacation, I'm going to pull each one of the bolts to transfer case pan and put locktight on them. They keep backing off and leaking allot of oil. Pull the Ebrake same thing leaking oil real bad. (put it this way I had to add a whole container in a matter of a two days)

My question is I see my trans is leaking a little oil in front shaft because there is gear oil that is coming in between trans and bell housing, do I leave it see if it stops leaking or pull the trans?
Don't know why but everything leaks more with new seals, I guess the dirt and grease kept it from leaking...
My trans still makes noise in second gear but its getting better, so is the clutch, I think I should put return spring on like what was recommended to me.


Little side story: my brake pedal caught the sheetmetal I think on floor and I lost my brake for a second in the parking lot damn that gets you going, the wall and jeep would of tried fighting not sure who would win. I don't want to ever find out either... So I got to find were it got caught up

 

That is a shame about your new windshield. With all the jeeps in California, hopefully you can find a used hood at a salvage yard. Whenever I see this happen to an early, I am glad my 71's hood has a safety catch.

 

im just glad everyone is ok!

sheet metal can be fixed...

WHEW! i had that happen 1x... was THE most scary thing i have ever experienced

make sure to remove the seat padding from between your cheeks!

 

x2 on the safty latch. My buddy, however, had his hood on his cj7 do the same thing. Luckly, nothing was brock and it just creased the hood a little bit (must not have been going too fast) and his jeep does have the safty latch...go figure. Im sure i missed it somewhere, but what transmission are you running in your jeep? Also, with the good work you have done thus far, im sure you will get it buffed out in no time at all.

 

Homerdog: one would assume parts would be easy but every time I call the wreckers I get expensive prices. I will keep my eye on Craigslist though

TexasBlues: I think it's scarier almost sliding in a ditch, but I think it would of been a different story if I was on the highway and knew there was cars behind me

'72cj5: I got a t-14 transmission, and I hope to get fixed soon. That's interesting about the cj7 with a latch.

 

Got my transfer case to stop leaking for most part, Bolts kept backing out. This allowed me to take the jeep for a short trip, 60 miles. I'm getting horrible gas mileage, I had to adjust points real quick to get the jeep to start and so I got to re tune the engine. /

anyways, Trip went real good 20 miles offroad. 40 on backroads and highways, My carb cuts out at 55. (vapor lock maybe or it needs to be rebuilt)




couple more pictures here if your interested.
http://s602.photobucket.com/albums/tt105/piffey263/cj5/Cow Mountain/

Jeep does 55 great with tire pressure at 25, until it gets to hot and then carb starts cutting out... I was surprised 10 psi makes a huge difference.

Anyways after this trip, I figure out exactly what I have to do....
Fix my rear brakes (I got the hub puller on order along with tierods, shocks)
Pull my master Cylinder (Started leaking all the sudden) not much but enough to pull
after I parked the jeep, my transfer case decided to leak all the oil.
So, i'm going to pull the transfer case, and trans to check to see whats going on. Also, got to make a return spring bracket for clutch.

I pulled the steering wheel and I'm going to finish that.
I now own a new 1 1/4 socket, and the bearing puller from my trans rebuild works nicely to pull steering wheels.


My hardware store was closed, So I couldn't get smaller bolts.. Strap and long bolts had to do.

1/2 socket extension works well for putting in the hole so the puller has something to push against.
Couple taps with a dead blow hammer and some PB blaster, the wheel slide off nice and smooth.

Also, I installed a horn. I almost got T-boned by a new Camaro, so that made me get a horn. Although I should just use the growler that's on the front of my jeep might work better. hmm, lost those pictures I will have to take some more then.

Picked up a stock gas tank from one of our members and started installing that too, Need to make a return line... also, need a fuel pump. Kragen doesn't have one for 66 but for a 70 they have one for $20 go figure...
once I have the lines and such done, I will paint the gas tank black.

 

looks great and what fun it must be to cruise all that cool country...

not a whole lot of that kinda country here...

i go t a puller from HF too! well worth the $ for the prevention of the dammit-wrench usage...

 

jeeze Piff I am glad you are making progress but the next time some one is selling some seats one here you need to get them, yours are looking rough!

 

TexasBlues: It is fun if your leading, however my dad had two dogs with him so I had to eat dust... haha next time the dogs aren't coming and I should make latches for the full doors I got to have a semi closed cab with a bandanna and goggles.
That puller is the best money I ever spent on a tool, next to the breaker bar I breaker bar I bought.

Homersdog: I agree with the seats, Funny thing is I know how to sew on a sewing machine.... but I can't find a sewing machine good enough that will sew canvas. I want some really nice seats but I don't have $300 for a set of new smitty's or $800 for mastercraft (I would love mastercraft on account this is my daily driver)
I should go down and get some hello kitty pillow cases or seat covers and throw them on? hellokitty

Got some updates: They aren't much, I told doctor I would take it easy. Got a hurt neck right now, nothing serious but I don't want to make it serious. On bright side forces me to study for my EMT test even more.
I got to remember to use my camera, Iphones take horrible pictures hence why have my pictures are blurry.

Now that I got the steering wheel off I can add some more JB weld to the bottom so the turn signal works correctly.



Fills in the large chunk missing, so the wheel on the turn signal won't catch and not work. I always leave my turn signals on its embarrassing....
Tomorrow, The jb weld will be dry enough to sand with a mask... (learned my lesson I know better which is the worst part)

Started Disassembling pedal assembly, from what it looks like the whole shaft moved. Which would explain why I got over 1/2 of pedal slop on the brakes, and the clutch binding. I will figure out what to do once I get it completely disassembled.
This is how my clutch pedal is sitting now, If you ask me its not supposed to be that far over...


This is how I imagine it should be

As you can see it looks like the inner shaft its moved inwards? ​

when I took of the clutch pedal I completely forgot that I had to make a woodriff key,




I just got to share the gas tank, I think I will paint it black but I kinda like the red.





Finally, my horn. Took some thought to install, instructions are what made it harder.





cheap horn from O'Reilly's I bought the slightly more expensive one and its loud,

Broke out the soldering gun and heat shrink,


I'm getting to much electrical additions so I decided to start adding fuses. Doesn't hurt adding fuses.

 

The hood latch problem got me thinking. How about a light or buzzer wired to the ignition switch and circuited through the hood latches. When the hood latches are closed, it completes the circuit and everything is fine. When the latches are open and the key is turned on, the circuit is broken and the buzzer sounds. This may be a beneficial mod, I wonder if anybody has done something like that before.

 

yes, I wonder too. The idea though is brilliant, I think like a seatbelt buzzer would work. If i remember correctly my dads YJ was slightly delayed so it wouldn't be so much of a pain.
I think I will give this some serious thought.

 

I agree its a problem that could be addressed. I Don't know if its been done on an old jeep, but is certainly done on modern cars. For the jeep it would probably be easier just to get a hood safety catch used on the "late" earlys and putting them on the "early" earlys. Eliminates the need for more wiring, and sometimes jeeps are loud, hard to hear a buzzer.

 

homersdog: I agree that the jeeps are loud, but when you start a jeep up and its at idle. I imagine you could here a buzzer of some sort. That is another way is to Incorporate a safety latch of some sort. haha sheet metal work or wiring... I suppose this is one of those things that has many solutions for the same problem.


I got some parts in mail a while back
I can't believe I waited so long to get a factory service Manuel too.



Got some front shocks, Tie rods ( I didn't realize that I got two drivers side tie rod assemblies I will call the company Monday), Fancy hub puller to do my brakes.


I used my breaker bar and a large socket instead of the handle on the hub puller, because the handle didn't fit for some reason, and I got better leverage with the breaker bar.
I found that my rear wheel cylinders were full of junk... So I got new wheel cylinders on there way. In mean Time I will flush out all the brake lines, Which will be easy now with a flare line wrench.




got to safe its hard taking those drums off, I supposedly have posi traction. after pulling off one drum I think I got something else because if there is enough force the other side will spin... like a open differential. (Im thinking there is some type of clutch pack thing in there. ) or I should figure out what exactly posi-traction is.


I also started installing my tie rod assemblies, Which I would recommend getting the tie rod separator tool at local flaps. There would of been no way to get those tie rods off.

old and unsafe tierods.. make way for new, and pretty. I think I will feel safe doing 55 now once I finish we shall see.


My apologies to everyone, who reads this, Bad habit of working on 5 things at once... I end up waiting for a part in mail, or a part to dry ext. I should work on one thing at a time but It never seems to happen.

 

here's my copy of the same book with about 30 years of grime added. and duct tape.


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Homersdog: that's cool you still have one of the original manuals. I wan't to be able to see all the diagrams but only problem is i'm afraid to touch it cause half the time I got greasy hands.


Got some work done today,

Tie rods, and shocks are installed. I still have to torque the tie rods, and attach clamps, but that will have to wait tell I can jack the front of the car




Say do think my shock is bad ?


judging by the way it looked it was forcing one side to be stiffer than necessary...

My master cylinder was leaking too, I tore that apart and turns out it was just some dirt that got into the seal. Should be good as new now


Kinda funny I took off the clip and could not figure out how to get the piston out, the washer got stuck.

its going to be interesting, having the jeep go to alignment shop soon.


my shocks came with some metal bushings? but they wouldn't fit so I left them out, the other shocks didn't have them either so I guess i'm good right?

 

hey all, its been a while sense I had a update.


I got my transfer case dropped, it was making a really bad noise in 4wd. So I'm taking this opportunity to twin stick the transfer case, and rebuild it.
got the master cylinder back in, brakes on. Then not much else, been busy.




I also picked up this guy off of ebay I love it. Next I got to get a 102 in whip antenna just for a nostalgic look and mount in the back.


yes 23 channels. I swear that is luxury

so does any one know what the middle and plus prong go to? I think plus goes to battery, middle goes to ignition, then negative is your ground. I am either going to solder it or go look around thrift stores, ebay, and my house for something that will work.

 

I finally got some new seats, I got the drivers side half way mounted. Passenger side has got to wait tell my friend can come up and visit so I can use his welder.


Starting the Rebuild of the transfer case




Those Harbor frieght bearing pullers are good, I think I have used this thing over 10 times now. Its not being used in the correct fashion but hey it work a quick tap with the dead blow and the bearing comes right out.


got the breather pulled apart and had to clean the gunk and such out of it, just got to put back together. I'm trying for a transfer case that is nice about marking its territory.




these dies are amazing tell it breaks. I went out and bought one from Irwin seems to do allot better, I got all the 3/8th bolts for the transfercase clean now, and the 3/8 holes are tapped and cleaned. Twin stick rails are installed too.



All new bearings in all set up, I had to go down to a shop and have the bronze bushing pulled it was worn in a oblong pattern. Guy charged me $20 I was happy with it, even made sure it was within spec for the shaft by reaming it down.

Now I get to call around town to see if I can get the shims for a dana 18 case if I can't I will give herm a call Monday. Installed the shims I had originally and there is no end play and the bolts aren't even hand tight... Tomorrow I will work on getting the clutch linkage moved and modified, along with finish the fuel pump installation.

 

Got some more work done today: It was the fuel system
Got a new mechanical fuel pump installed. I been running a eletric fuel pump, and a boat gas tank for a long time I will be happy to put the master cylinder cover back on.



Painted the guard too while I was at it.


Throwing some new rubber lines were ever I think needs be, Got to take off the return line again and flush it, any ideas what to use? bees and such got the return line gummed up.

tomorrow I will finish the fuel system, going to have to move the in line filter some were else, the new mechanical fuel pumps won't work with the filter after. I don't want to pay $20 for a fitting to make the outlet vertical.

 

Fuel pump has been tested and works I noticed I got one of the rubber hoses a little long I will trim that tomorrow.

took my transfer case to a trans shop because I couldn't get a dial indicator fast enough, the guy was nice enough not to charge because I had the bearing set right.


Copper pipe works perfect for doing this for the 1in 1/4 intermediate shaft.




transfer case is all sealed up and case vent is all cleaned up too, I will let dry till sunday. I will install tomorrow, and let sit so the trans to transfer case seals has a chance to dry before I fill.
In mean time, going to drop by wrecking yard. I got a list of small parts that I need. I'm getting so close to having it run again, might have to take a 30 min drive to play in some snow when I get it running again.

 

Great build, and really fast! reading it makes me want to finish mine up this year, you also seem pretty young like me too(i'm 15, 16 in a month) Keep the pictures coming, really fun to watch the progress!