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Northern Virginia Jeepers Association
May 23, 2018, 09:58:08 AM

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Author Topic: The Silver Bullet - resurrection of a TJ  (Read 2924 times)
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Jeepsnbuses
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The seller and trader of many things.
« Reply #135 on: April 20, 2018, 08:50:03 PM »

The Jeep is starting to fight back. Got myself into a pretty solid pickle tonight...

Pulled the C-clips and shafts from Zukeís donor D35 with no issues. Removed the backing plates and all was going great. Went to do the same to mine to move the backing plates over and this happened:





Somehow the cross pin bolt just...sheared right off. Iím not really sure how this happened and donít think itís a fault of my own. Maybe it spent all these years sitting in the carrier side that was suspended out of the oil? Could it even deteriorate or rust in conditions like that? I used a 1/4Ē drive wrench and the right size socket; definitely didnít put too much power onto it. Funny thing is it felt like it broke pretty much as soon as I turned it.

In the pic above, Iíve already tried to chisel and tap what remains around to thread it out. Itís going, but itís painstakingly slow. Iím lucky to get 1/16 of a turn at best. Before I get frustrated and do something stupid, anyone have any clever ideas or suggestions? Would really prefer to use this axle and not swap in the 3.73-geared D35 if I donít have to. At this point I canít even pull the carrier itself out to work on this on a bench because the cross pin prevents me from pulling the axle shafts.

In my book I consider this a tricky one. Any thoughts or suggestions would be greatly appreciated.

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2002 TJ Sport
Tow rig: 1973 Thomas school bus RV conversion. It's slow.

- Adam
zuke
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« Reply #136 on: April 20, 2018, 09:15:23 PM »

I'd bet that it was torqued in too tight previosly, and the crack was just waiting for you.... Drill a small hole and use an easy out if you can, but it's probably going to be slow going no matter how you do it....

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John
2017 BU Trailhawk
2015 JK Unlimited Sahara
2008 JK Unlimited
2006 TJ Rubicon
1999 TJ SE
1990 SJ Waggy
1989 XJ Cherocar
overhead
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Crap, someone call Trevor.
« Reply #137 on: April 20, 2018, 09:50:16 PM »

At that point. Do the axle swap. You're gonna chase a headache for however long you're gonna put into it. If you've bought em swap em

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The only thing about a Yj that's reliable is its mechanic.

Joey to Mike- That's more like it! Never done.....just outta money at the moment.

atjeep-Every time a YJ passes inspection, an angel gets it's wings.
Jeepsnbuses
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« Reply #138 on: April 22, 2018, 07:38:52 AM »

I got it out.

Went out and bought a Dremel, then bought a diamond tip engraving point for it. Carved a channel in the center that would accommodate a flathead screwdriver, then drilled into it again with a cobalt bit. Doing both of those things seemed to fracture the integrity of the screw enough to allow me to snag it with a tiny pair of needle nose pliers and spin it out. Thank the Jeep gods.



Then I could finally remove these backing plates! And holy moly were they jacked. I thought the one on the passengerís side was bad. Check out driver:



And then both bad plates compared to a good one (top). Whatever happened to these things, theyíve lived a hard life. I prompt retired them to the garbage bin.



Backing plates, brake lines, and wheel cylinders are on. Axle is back together but I just ran out of time fighting that cross pin screw. Feels like I got next to nothing done but at least that screw is out.

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2002 TJ Sport
Tow rig: 1973 Thomas school bus RV conversion. It's slow.

- Adam
highlandercj-7
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« Reply #139 on: April 22, 2018, 07:58:21 AM »

Great googly moogly, what in the world ate the plates up like that. Shocked

As for the pin I have seen that several times on the turdy 5. I have drilled and tapped them, and used a punch as you did. Fortunately enough they are usually loose after they snap and are easy enough to work with. Some of them do not even have a bolt they used a roll pin. Glad you were able to salvage it.


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HighlanderCJ-7
Jeepsnbuses
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The seller and trader of many things.
« Reply #140 on: April 22, 2018, 10:23:56 AM »

Yeah the plates were really destroyed. I had only pulled the passenger brake apart and initially thought it was in the worst shape. Driverís side didnít disappoint! The side-by-side comparo with the good backing plate is pretty amazing.

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2002 TJ Sport
Tow rig: 1973 Thomas school bus RV conversion. It's slow.

- Adam
zuke
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« Reply #141 on: April 22, 2018, 10:47:41 AM »

I'm amazed the thing even still rolled!

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John
2017 BU Trailhawk
2015 JK Unlimited Sahara
2008 JK Unlimited
2006 TJ Rubicon
1999 TJ SE
1990 SJ Waggy
1989 XJ Cherocar
Jeepsnbuses
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Posts: 1055
The seller and trader of many things.
« Reply #142 on: April 30, 2018, 07:48:31 PM »

Checked off some crucial to-dos this afternoon. Refilled the rear, installed and adjusted all new rear drum hardware while cursing up a storm, re-tapped the threads in the yoke of the front end, and installed the front sway bar end links. Oh, and popped in a shifter boot shroud! No more floppy loose boot.

Iíve been neglecting an important item...a battery. I pretty much always have to jump this thing and itís taken a toll on the battery (though itís the old one out of my XJ). Thatíll be next along with a brake bleed, then itís on to body work.

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2002 TJ Sport
Tow rig: 1973 Thomas school bus RV conversion. It's slow.

- Adam
Jeepsnbuses
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Posts: 1055
The seller and trader of many things.
« Reply #143 on: May 12, 2018, 02:59:23 PM »

Painted the hood today. Results were...meh. Body work and paint/prep is difficult and the hood is much bigger than it looks when youíre doing the work. Basically what Iíve ended up with is instead of a black beat-up hood, I now have a silver beat-up hood. Haha. One of these days Iíll probably come across an identical-ish colored hood on Craigslist and jump on it. Oh well.

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2002 TJ Sport
Tow rig: 1973 Thomas school bus RV conversion. It's slow.

- Adam
RFH_98TJ
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« Reply #144 on: May 14, 2018, 06:57:03 AM »

Send a note to Scott and Damien.  They part out all the time and would probably call you as soon as they have one.

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98 TJ 4.0 Sport 5-speed - 4" lift on 33s, 4.56 on D30 with Lock Right and Ford 8.8 LS, more stuff to come

- Frank
Jeepsnbuses
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The seller and trader of many things.
« Reply #145 on: May 14, 2018, 03:33:37 PM »

Going to try malleting-out my outgoing good as well. It isnít worth anything to me at this point so I figure itís worth a short.

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2002 TJ Sport
Tow rig: 1973 Thomas school bus RV conversion. It's slow.

- Adam
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