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Old August 16th, 2012, 11:44 AM   #1
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Default 1ton YJ refresh/rehash

I couldn't take it anymore, waiting for my multiple projects to finish themselves so I could go wheelin....so I bought another one.

This one:

The only CTOR bought not built


...which after a few years of use needs a little TLC.


Hauled it home and moved it around a bit, looked it over and started making a list.

Rear axle pinion seal is shot Done, had to put a redi-sleeve on the pinion yoke
Passenger hub seal is toast Done
Passenger rear hub is loose, bearings thrashed on passenger's rear hub, pitted and missing rollers on driver's rear hub. All new bearings, had to peen the ID of the hubs to keep the races in place, the pass hub had to have the ID opened up a bit right at the axle bolt flange to get the outer wheel bearing race in...it's egg-ed out a bit. Both rear hubs are pretty much shot, had to weld the wheel studs in, and the pass-side spindle needed some heavy work with a file to get the bearings back on...REAR AXLE IS GOING TO NEED WORK IN THE FUTURE
Need to check rear R&P, drain, refill etc. Done, gears look great, welds appear to be holding.
Rear brake calipers froze up and pads are pretty thin Done, new calipers, pads, flex lines, banjo bolts, and one hard line, cleaned up the rotors
Front driveshaft CV has a broken cap and is pretty whipped Done, CV centering ball was good, as was the end joint at the axle, the joints in the CV were factory wth the plastic retainer...fun...should have tack welded the dust sheild on the centering ball....it clicks with every rotation...annoying.
Rear driveshaft is the "trail spare", "good" rear shaft has cracked CV centering yoke Done for now, "Good" rear shaft is rebuilt with new u-joints, centering ball kit, and spline seal, but it is a touch out of phase, might build a new one and re-phase this one later.
Driver's side motor mount is cracked and bent Tightened up all three bolts...two were almost out...I'll keep an eye on it but I'm sure the weld cracked because the bolts were loose.
Need to check front R&P, drain, refill etc. Done, gears look great, teeth on the Lock-Rite look decent, both diffs appear to have been serviced by the master of RTV...both covers had to be pounded/chiseled off...nice job whoever! They will probably leak when I am done.
Need to check out front axle. Pulled it apart, no real surprises....yet
Passenger front caliper is stuck and the bleeder is a lump of rust about to break off, pads are iffy.
Driver's front caliper appears new-ish, pads are nearly new.
Done, new calipers, pads and rotors.
Passenger drive flange holes are egged out. Actually they appear to be drilled for 7/16" bolts, but the hubs are tapped for 3/8" bolts...no wonder two bolt broke off on that side.
Passenger hub has two drive flange bolts broken off in it. Done for now, drilled one out with no damage...fubared the other one, going to run it with seven bolts for a bit and try to find a different hub or put it on a Bridgeport. Indexed a new pattern of 13/32" holes in the drive flange, bored out the fubared bolt and saved the 3/8" threads.
Spindle bearings and seals are iffy on both. Done, new spindle kits on both sides.
Shafts look good, axle joints look good.
Passenger outer shaft has some blueing at the spindle bearing surface...never seen that before.
Front spindles are a little beat up
Done for now, all cleaned up and re-assembled.
Need to drain and refill T-case...just because Done
Need to change engine oil....just because Done...old filter barely came off in one piece
Very few of the guages work, gas guage dances around
Dash wiring is pretty hodge-podge.
Rear of the tub is quite damaged and is no longer supported at the rear sill
Couple of the lower links are bent, heims are pretty loose, front lower JJ's are shot.
Tie rod heims are loose
Drag link is bent and loose
Passenger front coil mount is bent
Passenger front shock mount is mangled Done for now, gave it some hammer love.
Leaks a bit of everything from everything
Gas tank leaks bad when full
Vibrates pretty bad over 45mph..probably rear driveshaft.

More to come, but the plan is to lightly go through the whole thing, clean and repack bearings, drain and refill fluids, rebuild driveshafts, and go shake out whatever weak spots I can find.
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Last edited by 4Bangler; September 30th, 2012 at 08:55 AM. Reason: Progress
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Old August 16th, 2012, 11:58 AM   #2
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hmmmmmmmmmm sounds like a perfect wheeling rig already broken in. Congrats to both you and the Junkie.

BTW, will you be screaming when you wheel?
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Old August 16th, 2012, 03:43 PM   #3
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Just got a e mail from ruff stuff, heims are 20%a off till sunday
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Old August 16th, 2012, 05:39 PM   #4
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Originally Posted by whiterhino View Post
hmmmmmmmmmm sounds like a perfect wheeling rig already broken in. Congrats to both you and the Junkie.

BTW, will you be screaming when you wheel?
No screeming, but the occaisonal "Oh shit".

I actually thinking of painting it Black, there's way too many old 99%'ers driving white YJ's....I don't want people stopping me asking for your autograph.

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Just got a e mail from ruff stuff, heims are 20%a off till sunday
Got the same one, probably place an order tomorrow.
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Old August 16th, 2012, 05:50 PM   #5
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Originally Posted by 4Bangler View Post
Now screeming, but the occaisonal "Oh shit".

I actually thinking of painting it Black, there's way too many old 99%'ers driving white YJ's....I don't want people stopping me asking for your autograph.



Got the same one, probably place an order tomorrow.
I'm thinking this is actually why Josh sold it.
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Old August 16th, 2012, 05:59 PM   #6
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I'm thinking this is actually why Josh sold it.
That and i was startin to look like you......old
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Old August 16th, 2012, 08:57 PM   #7
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Worked on it a bit....a very little bit...damn rain.

Step one was removing the CTOR club sticker....I don't want my shenanigins soiling that club's spotless reputation....so I put it on my garage fridge...



Then I pulled the shafts and hubs off the rear, shafts had a slight twist but I'll keep running the 30spline stuff until I exhaust my supply of spares (4)...driver's side hub and spindle was in good shape...



...passenger side....not so much....



...the inner bearing was non-existent, the race was seized to the spindle, the outer bearing cage was brocken, and the whole thing was a congealed mess of gearlube, mud, and metal chunks. I cut the inner race off and cleaned the spindle up as best I could, looks salvageable. The caliper slide pin was also grooved up from the rotor dragging on it.

Cleaned up the hubs and chased the wobbled-out axle flange holes...


Tried to decide which of the not quite right wheel studs was a better choice...decided to leave it as is and weld them in...


I'll get some new parts and hopefully have her all buttoned up this weekend. If I can get some shake-down time early in the week I might take Friday off and haul it down to the Badlands for the TREC and WEROCK event....we'll see what else I find. ..not even close...
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Last edited by 4Bangler; August 28th, 2012 at 11:50 AM.
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Old August 16th, 2012, 09:50 PM   #8
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I'll be watching
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Old August 17th, 2012, 11:58 AM   #9
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Congrats!!!
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Old August 17th, 2012, 10:41 PM   #10
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Way to pull your sticker like your supposed to TJ .
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Old August 18th, 2012, 07:25 AM   #11
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Way to pull your sticker like your supposed to TJ .
I promised him it would be the first thing I did when I got home....he was too busy trying to locate the title.
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Old August 26th, 2012, 09:01 AM   #12
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Made some progress, need to get the passenger rear caliper to stop leaking from the banjo fitting so I can bleed the rear brakes. Next up is drive it to the coin-op carwash for a thourough underbody wash....which should have been step one. Then it's on to a quick (hopefully) refresh of the front axle and off to do a little wheelin.

Also discovered during the whole rear-axle rebuild fiasco that the Chevy 60 uses smaller wheel bearings, smaller wheel bearing hex nut, and therfore a smaller OD spindle....too small to be bored out for 35-spline.....balls....guess I'll formulate a plan B. I might look into cutting the spindles off the housing and welding on Ford Dana 60 spindles, I have extra Ford hubs and lots of Ford 30 spline shafts, so I could do it as a stepping stone to 35-spline. I would be out the $250 worth of wheel bearings and seals for the Chevy hubs though.
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Old August 26th, 2012, 06:43 PM   #13
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Returned a faulty reman caliper (really, that's how my day is going) and put her all back together, bled the brakes and got ready for the first real drive...

....until the driver's door wouldn't open. Futzed with it for a bit and realised it was just barely off the "unlocked" position on the inside handle and that was enough...dumb.

Started it and looked over a few things, got in and it quit...crank no fire...add gas....still no fire, pull the air cleaner, it's getting fuel, just no fire...scratch my head and try it again, fires right up...wierd.

Ran fine to the car wash and back, only other issue of the day was that I closed the hood on one of the hold-downs and the center latch latched...had to hammer the center latch with a chisel to get it open again....this Jeep just might hate me.
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Old August 28th, 2012, 11:51 AM   #14
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Made some progress last night...maybe I'll wheel it by the weekend...

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Old August 31st, 2012, 10:25 PM   #15
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Getting closer, the front axle is ready to go back together after a quick wire wheel and rattle-can rebuild. Hopefully I will be driving it again by tomorrow afternoon.
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Old September 1st, 2012, 07:34 AM   #16
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looking good keep up the good work!
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Old September 3rd, 2012, 06:30 AM   #17
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Progress has been cattled once again...I packed the bearings and reassembled the front hubs only to find that I inadvertently received 1-1/2" thick Chevy rotors instead of 1-1/4" thick Dodge rotors....duh...didn't even check them, and they won't fit. The correct Dodge ones won't be here until Tuesday or Wednesday.

Since I live in Big Dumb Mud Truck land, I had to buy some Big Dumb Mud Tars....so I scored a set of new 38.5x11-16 Boggerz and intend to mount them on the OEM wheels from my '05 Chevy 3/4-ton.....but the wheel center hole is too small for the big dumb Dodge hubs on my front axle....so those will have to go out to the machine shop to get opened up....I think I will have him index a new set of 3/8 holes on my driveflange that has 7/16 holes too.
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Old September 10th, 2012, 11:33 AM   #18
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Sucess!!! Finished up the "short list" of items I deem necessary before I could run this thing and drove it to work last Thursday afternoon....brakes are still a little iffy, maybe master cylinder air leak...maybe it needs an adjustable prop valve...we'll see.

After work I trailered it out to the local Optimist club's obstacle course to try it out a little....



...and found that I can loose a front coil like it's my job....



...but all in all it performed great and with a little "getting to know you" time I'm sure it will suit my needs just fine.
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Old September 10th, 2012, 11:40 AM   #19
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I booty fabbed upper coil retainers out of some tractor supply carabiners and a couple links of 3/16 proof coil chain....coils don't pop out anymore, but I will probably clean this temporary fix up later.

I slapped on my Big Dumb Mud Tars (38.5x11-16 Boggers on 16x6.5 OEM Chevy 3/4-ton wheels with the center hole opened up to 4.774") and went to a local mud party to remind myself that I don't like running in mud....



...the Jeep did great all day, found a bunch of sand hills and undercuts to climb/launch off in between taking passengers for rides through the mud pit. The skinny Boggers owned the day and the old farm truck 350 never got over 220....I never even got stuck....but I did have to back up once. Maybe it's not running in the mud I dislike so much....but I sure HATE cleaning up.

Jeep LOVES climbing and feels quite stable, I need replace the driver's window crank which is now stripped, and wash in the interior intensely.
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Old September 10th, 2012, 11:44 AM   #20
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where are the boggin pictures!!!
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