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Build Thread Aussie CJ7 - 78

Build Thread Aussie CJ7 - 78
JAG811

JAG811

Senior Jeeper
Posts
653
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Location
Cairns, Australia
Vehicle(s)
'57 CJ6 & '78 CJ7
It took some time to find the old girl. I spent over a year looking for a clean CJ7 79 that wasn't going for a ridiculous price.
I found an ebay CJ7 - 79 that hadn't reached it's reserve. Long story short - I picked her up for a good price. Checking the plates I soon realised she was a 78 production, registered/sold in Aus in 79.
Spent the first couple of weekends smashing it around the hills up here, and I soon realised if I was going to rebuild her, I wanted to do one job at a time and keep her running so I could head up the hills with the dog every now and then after a big day at work.
So I devised a cunning plan. :cool: underbody first. Clean and restore everything undernieth first, and then pull the tub off at the end. Galv dip the chassis then.
There would definitly be some double handling ... but I thought the idea of scooting down the river in her on a Sunday through the middle of the restoration was worth it.
First job was to pull out the big BBQ bottle in the back. This ment I had to drop the petrol tank out to get to the BBQ bottle bolts. Pulled the tank out to find a big clown patch welded in.
And with thus the restoration began on Australia Day 2011.
 
Choose to dip fuel tank skid plate - But I put in four more matching drain holes as it was clear there was water geeing stick and corroding the skid plate.
Bought a new tank and sender.
 
I put the new sender in and messed around for a bit getting the length of the pick up filter. I had to do it twice though as I wasn't happy with the seal the first time as it seemed pinched.
I had to re-cut the threads on all of the pieces that had been galve dipped. I put the skid plate back together and painted away.
 
I spent a hole day waiting for paint to dry ....
I left the plastic rejuvenater on over night and then cleaned it up.
 
Fuel lines on and she went back in.
I cleaned up the underside of the tube and sprayed some under body spray to prevent any further corrosion over the next six months until the tub comes off.
 
I've got the Transmission skid plate off at the moment.
I've got some new Transmission and torque arm mounts on the way and I'll drop it in to be galve dipped on Monday.
I've found a really slow oil leak on the QuadraTrac . Not at the end of the auto. There seems to be a 2" adaptor style piece and it's leaking on that seam.
If anyone has any picture breakdowns to post it would be greatly appreciated.

Cheers,

Jon
 
You'll see now from what seam the QuadraTrac is leaking from.
So I'll mark the drive shafts tonight and pull out the Transfer Case .
Again, if anyone's got any advice please post.
 
This is going to be a good one to watch. keep us posted with pics. :chug:
 
I cleaned up the shed last weekend. It was a case of the day after a very long night fueled by bourbon and cards with good friends.
I whacked together a roller for the hard top .... I had some pieces of timber lying in the rain and some rollers on the bench.
I'd like to cover it in some carpet and it needs another piece screwed into the top piece to straighten the angle of the hard top up a little more........ I have to see if the JK will fit on too ?? icon_wink.gif

I also changed the coolant and pulled all of the heater hoses off. I'll pull out the heater in time as I plan to swap it with a Heater/AC unit. No more rusty brown coolant.
 
So the skid plate was the first thing off and there was oil everywhere. Not happy again with stock drain holes I've put in more drain holes. You'll see where "stuff" was collecting even though I'd degreased the hole thing 3 times. She's ready now for galve dipping.
I had two annoying dints in the tailgate and although I'm going to rhino line the tub and the inside face of the tailgate and shouldn't have let it bother me I couldn't help myself. I filled the dints and brought it back. You can see the slight spots left from the welding but when it's dipped it should cover these in just fine.
 
The exhaust shield was really frustrating pulling out the Transfer Case . I'd recomend it's removed before pulling out the Transfer Case to avoid the amount of swearing I did ... :rolleyes:
I pulled it off and found it cracked so I cleaned it up and welded back the crack. I welded on the nuts too so that I would have no difficulty putting it on and off from underneath the vehicle. I also took some off the shield so that the Transfer Case should go back in a little easier then it came out. She's now ready for dipping too.
After I'd degreased the Transfer Case 4 more times I brought her in. I tried a couple shinning products but once I hit it with the wire brush and some elbow grease she started to take shape. I've thrown in a little sneak peek picture.
 
QuadraTrac Seals

Ok so the first picture will demonstrate where the leak was from.
On the back of the Transmission lies an adaptor plate. I had a slow seeping leak (Transmission oil) from what seemed to be between the adaptor plate and the QT.
First step was to get the QuadraTrac out.
Four bolts and the Qudratrac should be off.
Once off it became obvious I had a problem with the back to back seals that should stop the Transmission oil entering the Transfer Case .
There was however no gasket between the Transmission and Transfer Case which all pictures of seal kits indicated there would be ?
 
First picture is the closeup of the back to back seals. I found the first one split and both seals brittle and needing replacement.
The QuadraTrac is NOT a light Transfer Case by any means and takes some lifting onto the bench .. :eek:
You'll need to remove the 4WD indicator switch to continue as it will impede undoing one of the bolts.
Also there is a couple longer bolts through the "high low" unit you'll need to pay attention to.
 
QuadraTrac Seals

With the QuadraTrac split it was time to try to get at those seals again.
I had gently tried to pull them out before I split the case.
At numerous failed attempts I thought they must have only been able to be tapped back into the case to be removed.
It turns out you can pull them out without splitting the case. I would recomend splitting the case though and the next post should indicate why - There is a drain well you need to place both seals either side of.
I tapped the bottom seal through and then the top.
 
QuadraTrac Seals

First picture demonstrates where the well sits between the two seals.
Second picture demonstrates where it will allow the oil to run out, down between the Transfer Case and Transmission adapter/mount plate.

I took a photo of the original seal part number for everyone to use. I just took it in to a bearing specialist and he plucked two alternative seals off the shelf.

Old seals out, new seals in.
 
QuadraTrac Seals

You'll need to take some care tapping in the seals. Second picture shows the well is exposed after tapping in the rear seal.
Third picture is both seals in and ready to slap em back together.
I used a high temp silicone as it was a flat surface with no rubber ring seal as I also thought it would be.
Take a lot of care to place the Transfer Case back together getting the output shafts to line up as they were before the case was removed.
Last photo is of the QuadraTrac on the floor where I could get a good grip to tighten her up again.
She's heavy, and it's like trying to stand an egg up ... :rolleyes:
 
This is the finished product .. two coats of clear.
I figure with the clear dirt and grease should wash off easier :rolleyes:
 
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