Front Suspension

Time to take apart the front end, first to go is the steering rack.

Then after taking off the brakes and springs, the front cross member is dropped.

Off come the dampers.

And then the A arms and other bits.

I got the media blaster fired up and started cleaning parts, first up, disk brake dust covers.

Next are the upper spring perches and bump stops, then they got the POR-15 treatment, fugetaboutit.

Drivers Seat

Welcome to another episode of This Old Seat Cushion. This particular cushion felt like it had given up long ago.

The new cushion doesn't look that different, but is displays some real bottom support.

That might have been the easiest task in the restoration, so far, but probably in totality. 

Rear Axle Part III

Rear axle back from media blasting, and steel epoxy reapplied.

Old axle droop stop anchor removed and new one welded in place. I think we are ready for paint.

Well, not paint, POR-15, two coats, good to go. Reassembly of brakes forthcoming.

Rear Axle Part II

The corrosion from the bump stops has been cleaned up and filled with JB Weld metal filled two part epoxy that hardens to over 5000 psi.

The next issue is the droop strap hanger, the end is broken off and there are only three threads left. We can fix that.

One and a quarter inch steel stock, an hour on the lathe, and viola, a new hanger.

Some new 3/8 by 24 threads and it's done. Well, it needs to be welded on, that will happen when the axle comes back from the shop where it is getting media blasted.

Transmission Part II

A new first motion shaft bearing installed.

First motion shaft in place with new gasket. Not so fast, we need some new shims for the front cover. We will revisit this part in a few days.

   

Third motion shaft, with new needle bearing and synchro rings installed, and laygear in place.

Selector rods installed with new safety wire on the first/second gear selector.

Laygear shaft in place with thrust washers and new needle bearings. Reverse gear in place.

Speedometer drive in place with new gasket and a bit of form a gasket as well.

Output shaft torqued and lock tabbed.

That once dirty mess is now a refreshed transmission. When I get the shims the front cover will go on and it will be done.

Valve Rocker Assembly Rebuild

Time to rebuild the valve rocker assembly. First step, press out old bushing from rocker.

Bushing removed using custom press die I had to make on the lathe.

Old and new bushing, oh yeah, the bushings need two oil passages drilled.

Drilling oil passages.

Both holes drilled and match up to the old bearing.

Set up new bushing making sure the oil holes line up with the rocker arm oil holes.

Pressing in new bushing.

New bushing installed. All done... not so fast, they also need to be reamed to fit the new rocker shaft.

Hand reaming the bushing, it takes about six passes to get it to the correct size.

Reamed to fit.

Success, the shaft fits through the new bearing with no play but free rotation. Now repeat process seven more times!

Eight old bushings removed.

Ready to assemble. Note the wear on the old shaft shown up front.

Rocker assembly complete, all new bushings installed on the new shaft. Ready for another forty years of service.

Transmission: Part 1

Oddly, removing the selector fork proved to be the most difficult part of the disassembly, but it did come out.

Rear extension removed, selector rods and forks coming out.

After the laygear shaft is removed it lays low enough in the housing to then remove the reverse gear.

Reverse gear and shaft out.

The input shaft or first motion shaft just pulls out once the front cover is removed and laygear is sitting at the bottom of the transmission housing.

Next the output or third motion shaft can be removed from the back of the housing.

And voila, an exploded transmission. In part two it will get put back together with new needle bearings for the third motion shaft and laygear shaft as well as four new synchronizers, they all seemed to be pretty weak but more to the point, they are 46 years old, why not replace them while it is taken apart?