Posi's Do-over

What u-bolt plates did you use for your springs?

 

Rubicon Express plates. I bought them from Foothill Offroad.
https://catalog.foothilloffroad.com/index.php?cPath=21_27&osCsid=6df26fb6d7468f5d30d9dfb4d95a0b14

 

Ok thanks. I clicked the link yet see there are no ite.ms in the catagories

 

Hmmmmm, don't know whats up with that. Try this one: http://www.rubiconexpress.com/BuilderParts/

 

So, I got the t-case out today. Here you can (maybe) see the studs I use to hold the t-case in place after the last bolt comes out. I use them to re-install the t-case too.




Here it is on the bench.


Here's the culprit. Some of the case hardening has come off the intermediate shaft. The rollers looked OK, but I ordered a complete re-build kit. I figure with it this far apart I might as well do it all. Also, because I boxed the frame, the speedo cable was really bent at a sharp angle going into the output cap. You would think the cable would just twist and break, but instead it stripped a bunch of teeth off the speedo gear. All that went into the case too and may have contributed to the wear.


No guts....no glory.


Tomorrow I'll take the case to the carwash and douche it real good. The smaller parts can go into the parts washer.

 

LOL!! If thats all it is I will just order some and slot them myself. Didn't think of that.

 

I have the same driver's side exhaust manifold on my '71 CJ5, the ports are mismatched. What did you do? I'd like to see pictures of your exhaust, manifold on back. You have a really nice build! David

 

Here's the link to the thread I started about this problem.
http://www.earlycj5.net/forums/showthread.php?90574-Buick-Manifolds

Seems to be working for me now. I'd take pics of the rest of the exhaust, but I'm going to have the muffler shop redo it. Right now I have dual pipes all the way back past the t-case, then they come together and flow into a muffler at the rear. I get a lot of resonance from the system and it's annoying. I wanted quiet. I'm going to have them run one side into the other under the engine pan or somewhere up front and them one pipe back to the muffler. Probably won't happen until Spring. It sounds good up tp about 2400 rpms than I get the brrrrraaaaaap. Definitely get the header gasket set from Summit. They offer way more sealing surface than the stock gaskets.

 

Got that big pig of a tranny out today. Put the empty t-case back on it along with the housing for the OD. I want to put everything back together before I put it all back in and I wanted to be sure I could squeeze it out past the exhaust pipes. Now I know it will fit back in. It's difficult enough re-installing the OD snapring as it is, I really don't want to do it while I'm laying on the ground under the Jeep.

 

Glad you found the problem, and I couldn't agree more. Just put mine back together, what a pain!

 

Even the special washer can be difficult on the Saturn, let alone the snapring.

 

Roger that! I'm going to stand the tranny on the bellhousing and put the t-case and OD on in that position. Should be a lot easier than with it horizontal where you can hardly even see up in there. Then all I have to do is manhandle that monster into a position I can hook the chain hoist up to it.

 

I think the biggest challenge will be getting the OD nut to torque with it out of the vehicle. I'm going to put a rod through the front yoke so it can't turn and hit it with the impact gun. The Saturn, unlike the Warn, only has one spot for the little dong on the special washer to go into. So you have to get everything lined up just so for it to go in.

 

Impact gun is pretty hard on gear trains.

A cheater bar would be a lot kinder on your tcase

 

Point taken.

 

Got the drivetrain back in today. But no early enough to wrap it all up before the impending storm that's predicted for tonight. Took quite a while to get the special washer in place for the OD. Unlike the Warn OD, the Saturn has a recess cut for the tab on the special washer that is actually under one of the planetary gears. Makes it a challenge to get it in place. That's the main reason I chose to assemble the entire setup while it was out of the Jeep. Now I'm having a problem with the clutch slave cylinder. The piston is not extending out all the way. Not sure if it's residual pressure in the MC or something with the slave itself. With a high forecast of 29 deg for tomorrow I probably won't get it figured out until Sat when we are going to "warm up" to 39 deg.

 

Glad to hear you got it all back together John. It's been a few years since I had my saturn OD apart, but I remember having trouble getting that special washer back in too. Raining here right now and cold too.