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Build Thread Aussie CJ7 - 78

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Build Thread Aussie CJ7 - 78
Looks good. :notworthy: It has to take some patience waiting for your parts to arrive down there. :eek:
 
1. OK it's in the bin with the old Transmission mount. The best part about the mount is the awesome custom bolts .... check them out ... unfortunately I was unable to get new ones and had to replace them with standard ones ..
2. Second photo demonstrates what joy restoring CJ's can be....when you push up the Transmission skid plate mounting bolt and the nut that should be welded into the chassis pushes straight up .... smashfreakB.gif I'll look at it later ... rolleyes.gif
3. Finally ... Onto the next job .... Pinion seals !!
It looks as though the rear has been leaking for EVER .. the front is not leaking at all but as I'm not looking at rebuilding the diffs before road worthy, just cleaning them up. So just pinion seals and at some stage some one piece axles .... icon_biggrin.gif I'll get to any axle seals when I look at the brakes ... which is after the suspension lift, ..... which is after these seals are done and I can put the driveshafts back in ... confused.gif
 

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Progress has been slow over the last couple of months with a lot of work done on the house instead ... Happy to say though ... the wet season is almost here :) this will push me back into the car port ;) regardless of the Mrs has to say !
 
JAG811 said:
Progress has been slow over the last couple of months with a lot of work done on the house instead ... Happy to say though ... the wet season is almost here :) this will push me back into the car port ;) regardless of the Mrs has to say !
Click to expand...

this reminds me i need to do this. :chug:
 
Thanks Kickitandholdit ;)

I've just about finished new booster assembly. Bought an 8" booster and master assembly off ebay and I just need to pick up a new proportioning valve now.

Same too, I have some springs waiting to go in, I just have to grab a bush kit.

I am however at a crossroads ..... is it time for the tub to come off ... knowing there's no turning back from there ... :cool:
 
So I'm back at it after a long break and way too much time at work ...

The new hangers are twice as good as the old ones - Pretty sure they're Warrior ones, but they were purchased some time ago.

So I've had new 2.5 inch springs collecting dust and I finally ordered a Energy Systems Hyper-Flex full bushing kit ...
So it's springs out,
Powder coat the shackles (so they are not shinny gold), diff covers and spring to axle plate.
Clean up both diffs.
Replace the bushes.
Half the reason I've been away for so long was deciding to frame off or not .. I'd really like to dip the chassis but it's simply not an option at this stage and I want to be driving the old girl again :(

Now when I went to take out the shackle bolts, to my surprise I realised that the way the bolts were in meant they would foul on the fuel tank and exhaust .... Why !!! Was it too hard to just turn the bolt around to have the nut on the inside ... Whyyyyy ???

Third picture .... I'm really hoping that's not a sleeve ... or once was a sleeve .. Bushes don't look that old so I'm hoping trained monkeys yielding spanners and smiling - Did not replace those bushes ....

Last picture is my current mess. I'm getting out the grinder tomorrow. It should fix a few problems I have with shackle bolts I now can't push back in :D
 
So while everything else is coming out (diffs) and the brake lines are undone, I'm also fitting a booster assisted master cylinder.

I don't know all that much about Jeep history in Australia but 78's and 79's (that I'm aware of) came out with power assisted front brakes only and the second picture will illustrate the bracket beside the washer bottle that the booster is mounted to.
I'd always assumed they were mounted in Australia after the CJ's were pulled off the boat. This is because it looks like they've taken both front brake lines and bent them up into a joiner and fitted it to the booster, and then run just the one line back into the proportioning valve.

You'll see the lines running up in the third photo.

Last photo shows the bad boy that arrived in the mail today.
I thought this way, because I have plans to go to 4 wheel disk, I can replace the proportioning valve now, and it will see through the disk conversion later.
 
Picture 1 -Shocks off - And they are simply there for aesthetic purposes only ... I could give them to my daughter to compress up and down. So Now I can add shocks to the next list :(
Picture 2 - Diff Breather off.
I undid the brake cables at the joiner. So I'll clean and paint that before putting it back.
I then had a hard time getting the rubber Brake Line undone up at the chassis. I couldn't see it and in fear of shredding the nut I cut the brake line adhering to the fact I'm going to need 3" lift extended brake lines for the next order too :(
Third Picture - Cleaning the diff. That's after degreasing, scrubbing and hosing three times. I then took the springs off and started with a grinder brush to clean up from there.
Last Picture - Soooooo .... so I'm worried the 2.5 inch lift springs may be lower then the springs I've taken out ... :confused:
 
First picture is springs off ready to clean the diff :rolleyes:

Second is after the first couple of goes flipping to diff over each time. It was then time to take off the brake line.

Third will show you how caked up the spring perches were. I had to re-drill holes and basically dig out half an inch of caked mud, grease and what else !!

Forth - As one of my pet hates is "anywhere water can catch and stay", you'll see I drilled out two drain holes in each of the spring perches so as to avoid any further corrosion due to lack of drainage in those perches.
 
First - Last coat all done. It's a Rust Converter, Sealer and Primer. So far - Awesome !!! But we'll need to wait and see how it goes. Says 3 days to properly cure. Really happy so far.
Second - Looking much more respectable.
Third - Really cleaned out those spring perches as best as I could. Then filled them full of the Converter. As you can see much better looking diff now !!!
Forth - You can see the drain hole, that I've now put in front and back of each spring perch.

So it's a flat black finish tomorrow. Gloss black for the park brake cables and brake lines. Try to see if I can get the diff rolled back under the old girl tomorrow avo.
 
So it's tools down - Weekend over :(
1 - All four spring plates are out with the shackles so they can get dropped off to the worlds slowest powder coater tomorrow.
2 - I do have a few problems though. Two of the spring hanger bolts are just spinning inside the chassis - :mad:
Left hand front eye bolt has rusted onto the sleeve inside the bush - :mad:
I can't get the brake lines off the front and they're the only things holding the front diff in now - :mad:
So, it's off to get a ring spanner this week. I'll pick up all the bolts on Friday too.
 
Just seems like a real shame to bolt this shcmicko diff back onto that :dung:ty, dirty frame :rolleyes:
 
Well I brought home a 3/8 pipe spanner and it's a looser fit on the brake line nut then my standard 3/8 combination spanner .... :confused:
I might give it a squeeze in the vice .. either way this is turning into a drama
 
So I spent most of last night looking for shocks ... I'm pretty sure these are what I'll go with,
Rubicon Express Twin Tube Shocks,
Only I'm going to look at the 4.5" lift set which from what I could find has a travel of 14.5" - 24.5".
They're very reasonably priced at $200 a set but if anyone has any thoughts, please let me know !! :chug:
 
Well even after I tightened up the grip on the pipe spanner by pressing it in the vice it wouldn't move the brake line nuts AT. ALL.
So as a last resort (fearing I'd make a mess of the nut) out came "old faithful" - Vice Grips.
Worked a treat and off they came !!!
Front diff - ready to start clean up tomorrow :banana:
 
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