What's that noise?

So any drive in a vehicle this, ahem, mature can lead to apprehension when a funny noise crops up. I was out on a recent nice day and just enjoying the drive when I noticed a "thunk" sometimes I shifted. Not every time, just occasionally. Everything was working, so I had no idea what it could be.

After she cooled off I slid underneath to look around.  Can't find a thing.  Nothing is loose around the transmission, or the drive train.  So of course I start worrying that my problem is internal to either the transmission, transfer case or rear differential/axle.

First things first, I decided to drain and fill the fluids in the transmission, transfer case and rear differential.  No metal flakes, so all looks nice there, although the transmission fluid level was low.  Very low.  A quick drive and good news is the transmission is very quiet.  I just assumed that continuous hum was normal for a Jeep...

The bad news was the "thunk" was still present on some of my shifting.

A few weeks later I was looking hard at the springs and used the drive shaft to pull myself further under the Jeep...the drive shaft moved laterally about 2 inches!  Not supposed to move laterally at all, just rotate.  This was NOT a good thing.

So I rotated the shaft and tried to recreate that lateral shift; no luck but if I turned it just right I could get a little lateral movement.  That meant to me the u-joint possibly was damaged.

So I removed the bolts and pulled the shaft.  Yep, u-joint had disintegrated.

Top of photo is the original u-joint.  All the needle bearings are gone, and the metal on the one end is so worn it wasn't held on by much.  A quick run to my local parts store and they had the replacement.  An easy install.

After torquing it all down I went for a test drive, and yes the "thunk" was gone.  Also gone was a vibration I hadn't noticed before, but noticed it wasn't there anymore.  She's starting to feel like a reliable and fun driver.

Thanks for looking...

Don't light a match!

What happens when you take a 45 year old gas tank, get a pin-hole, and then fill it up with gasoline?

Answer: a gasoline leak.

For months I was trying to understand why the Old Girl always had a gasoline fragrance to her.  Was it because her age, uses an old carburetor, so the fuel mixture is kind of "open" to the air all the time?  I lived with it, figuring this must be "normal" for car of her age.  Then the pin-hole became a real hole...

Did I mention the gas tank is under the driver's seat -- INSIDE THE CAB?

So one day I get in and there is gas sloshing about my feet.  YIKES!  I immediately get it all cleaned up and then start trying to find the leak.  You know, a full tank leaking into the car is just going to keep leaking, so I decided to drain it and start troubleshooting with an empty tank instead of a full one.  Only took a few minutes to figure that one out...



After draining it and a good inspection I realized there were a couple of holes where the drain plug is, which is accessible via a hole in the bottom of the tub.  Obviously some salt and moisture got up through that hole onto the tank, and it was around the drain plug that the gas was leaking from.

Choices:

1. Fix the tank.  Requires a bit of welding, have to get ALL THE GASOLINE out of the tank for safety.  Not expensive, but not cheap either.
2. Replace the tank.  Not expensive; can replace with either a steel or plastic tank.
3. Move the tank and replace it at the same time.  This gets expensive as it requires getting a later CJ tank that fits between the rear wheels under the bed.  Also have to remove some draw bar structure from the frame and need to cut some new holes either on the side or on the rear of the tub.  Lots of new tubing, hoses and other things to make it all work. 

I chose #2 and decided on a plastic tank.  Why?  I don't have to worry about rust and it looks original.

Only took an afternoon and works a treat.  As seen below, I've since added a double grounding; one to the body and one back to a grounding strap on the firewall.  More about that later...

I still have a bit of a gasoline smell, but it's nowhere near as bad.  Given it's a pressurized system I suspect it's not sealing perfectly around the gauge sender.  I've got a double seal there now, but may try something better in the future.  For now it works and I feel safe...with the window open of course.

Thanks for looking...

Nothing like a good charge

Sometimes it the little things...sometimes it the big ones.  

Let's talk the battery.  Actually, not wrong with the battery at all; lots of charge and turns over every time.  But sometimes you have to wonder if it is secured properly.  Well, the Old Girl has her original battery tray, but it's held together with not enough bolts.  Actually, only the one...and a bungee.

Yeah, I'm thinking that's not right.

So I find a replacement tray and some stainless bolts.  Very solid.  Looks sharper, too.

Best part: one less rattle when I drive.  Turned out the original was banging against the firewall at any speed above 20 mph.  It wasn't loud, but a "tic, tic, tic, tic..." with a squeak to go with it.  Now it's much much quieter.

Thanks for looking...

The girl is ready to romp!

So after figuring out she needed new springs - the originals were flat and provided no "spring" at all - I got a set and got started. But it's never that easy with this bird. 

Here's a before:

Note the lower line of the tub.

Turns out 4 of the 8 spring hangers were cracked. One very badly - I was a pot hole or speed bump away from a broken spring and all that THAT could mean. 

So I found me a welder and after I sandblasted all the paint (and even more Maine mud!) we got it all aligned and he fixed her spring hangars up good as new. I replace all 4 springs, plus the shocks.  Lots of air-hammer ratchet time to remove some of those rusted nuts.  

Now I can really go to town!  4 weeks of fighting rusted nuts and bent hangers all four springs and shocks are now replaced.

After:

You should notice she sits higher. I wished I measured from the ground, but it looks to be about 5 inches based on comparing the two photos and measuring those distances.  I have to really hike myself up to get inside!  

She'll get some steps for the side to make it back to original. Now I can see why. Of course, first I have to replace the exhaust with a stock system.

With this fix she's now safe to hit trails if I wanted (none around here so I'd have to tow her to Virginia or Pennsylvania).

Next major job is the steering. But I'm going to enjoy her for the rest of the Fall. 

Thanks for looking...

A little bling never hurt any girl

I was looking at my stock photo of the Girl when something said to me, "It's just not right."  I wasn't sure what so I started looking around the web at photos of Jeeps from the 1960's and eventually found some that had hubcaps.

Yea, that's the ticket, hubcaps.

So I searched around and found some on eBay.  Turns out there are many many different "Jeep" hubcaps out there so I had to be patient.

How many?

Doesn't matter, the "right" ones were stock from about 1969, the year she was born.

Looks great!  

Thanks for looking...

Thanks for looking...

Her rear end just doesn't feel right

Two things are important in the near term:
1) that rear cross member is rusted out and falling apart; needs to be replaced;
2) there is nothing between the front bumper of the jerk following too close behind me, and my rear lights.

So after spending a couple of days grinding rivets off the frame-to-cross member and cutting a couple of bolts (okay, 8 bolts!) the draw bar and cross member came off.  Above is the original.

The new one is just a C-channel steel with some holes and other cut outs drilled, and a little bit of bending and shaping.  turns out a guy in North Carolina makes a perfect replica for a very reasonable price ($100).

But for added protection (?) I decided to add a bumper to the rear end that would extend out beyond the tail lights and provide a modicum of protection.  I looked around and decided brushed steel tube looked best.  Of course, that was of the choices I had that would fit.

I'm not 100% happy with the look as it's not stock nor is it appropriate.  If I can find a similar bumper for the front, to balance the look, I'll stick with it.

Thanks for looking...

Something to hang on to...

There are two holes in the dash...okay there a lot of holes in the dash but two just stand right out because there is NOTHING in those two holes.

The CJ line has a grab  bar right in the middle of the dash, just offset to the passenger side.  Obviously for someone to hang on to when the road gets rough and considering that handles anywhere else were not very practicable (no roll bars remember) so having one on the dash sort of makes sense.

Problem is, there is NOT a grab bar on the Old Girl!  Two nice holes, in just the right place.  But what happened to that bar?

The answer is lost to time, but it turns out these are easy to get and I actually had a choice of 3 finishes:
1) Chrome;
2) Black (matte);
3) Primed and ready for the paint color of my choosing.

I chose Chrome:

Isn't that nice?

Thanks for looking...

That sexy look over her shoulder...

Mirrors.  And other details of course.  But let's talk mirrors.

Originally the CJ family had a simple post sticking out the driver's side with a small round mirror on it.  Then in about 1965 somebody at Kaiser decided to listen to safety advisers (aka the gov'MENT) and increase the size of the mirror.  They chose a rectangular job.

In the above photo you can just see it.  That's a photo from the 1969 assembly line in Toledo, Ohio.  Likely taken just before Kaiser SOLD OUT to AMC, but hey that's not my bag, baby.  But this photo plays a few roles in some other things I'm doing to make her like her original self.

Later in the '70's, I believe about '74, the rectangular mirror was replaced by two square mirrors, one on each side.  Enough on the history you say, what about the Old Girl?

Getting a perfect replacement for that style of mirror is pretty difficult, unless I can find someone willing to part with theirs...unlikely since the few that exist, exist because the owner wants to keep their Jeep original.  Otherwise most of those mirrors went to the same place the Old Girl's went: caught on some branch while on the trail, and subsequently the remnants were removed and sent to the local landfill.

So, I browsed the internet with my...browser, and found a pair of replacement mirrors.  I decided the price was right and got a pair, one for each side.  I doubt I'll ever install the one on the right simply because it would require tapping 4 holes, et cetera; and for accuracy she wasn't born with 2 mirrors so why bother?

So I've got this beauty mounted.  Of course after all the adjusting and getting it just right...can't see much out of it because of vibration.  Just a blurry mess.  Oh well, at least she looks good!

Thanks for looking...

Can I get the door (handle), Madame?

Okay, this is a bit of character.  The Old Girl saw some action in her younger days; some bits got ripped off by branches and other things while running through the Maine woods.

Like her mirrors...the spare tire holder...the side steps...and the left door handle.  But no need to fret; it's a simple door mechanism so any door handle works:

I believe that's available from the local hardware store, typically seen on some older homes.  The handle is glass with a square steel post and certainly goes all the way through.  Hey, it works!

So I decided to go cheap and got some nice handles to replace the existing ones; the passenger side still works but is corroded; I'll replace that one when I do some restoration work on the doors and top.

Much better and now it looks natural, new, almost like it was supposed to be there.  Of course, I still cannot lock the Girl, but why should I?  It's not like I keep anything of value inside her.  The "value" is really the Girl herself.  Any anyone with a modicum of hotwire knowledge can take her.

But then again down here in Southern Maryland she's the only one of her kind...so if someone takes her they need to break her up quick, which means she won't be worth much.  So I'm not too worried and besides, she doesn't get out of my sight much.

Thanks for looking...

Something better to cushion my rump

11 September, 2012

The original seats in the girl are done for.  I'm keeping the frames as I want to have them restored, and the photos show the original colors.  I believe they are Trim Package # 338 - Buckskin, but as is other things "not quite right" with the girl this isn't the right trim for the color (Omaha Orange).  For that matter, technically in 1969 or 1970 none of the production CJ-5s were painted in Omaha Orange, according to published options and records.  I suspect most of those "factory options" were for the Toledo factory, not the Ontario factory where the Old Girl was made.    

When I do the restoration I'll go for a material that is similar to the two colors here.  Not sure what I'd call those colors, but a brown and an orange-tan sound about right.

I went on line and searched for new seats.  My choices are not many.  I decided to go with Rugged Ridge front seats.  The color I got was "spice" as it looked closest to the original seat color.  The tan ones were too light.  The seats are for the intermediate CJ5, made from 1973-1980.  Other than how they are mounted, the tub should be the same...

After discussing how to mount the new seat in online forums I had resigned myself to basically having someone local fabricate (as in weld) a new mounting bracket for the passenger side.  The driver's side fit perfect as is.  Eventually someone who'd bought the same seats showed me the mount he made from steel angle stock, using just bolts.  His solution wouldn't work for me, because his seat mounted to brackets on the tool box whereas mine mounts to a bracket on the tub with different measurements, because I don't have a tool box.  Why Kaiser could not have used the same pattern on both seats is beyond me, as it would easily have fit and made it more common.  At any rate, looking at his method gave me inspiration and I was able to use 1/8th inch steel plate, 3 inches wide and 15 inches long to basically mount the existing bracket to the seat.  All with bolts so nothing was damaged.  I went ahead and sanded the rust off the old brackets and repainted them.  Real sharp.

I'm not sure I like the high backs.  I got them for the back support, although it ain't much; but they don't look stock.  I may regret this in the future, but for right now they work and it means I can drive her!

Thanks for looking...

Gas Cap and o-ring

12 September, 2012

I ordered new seats and few other bits and bobs that are just cosmetic.  Since I know I want to replace these items I just did it.

While I'm awaiting those things I'm doing a bit of troubleshooting to find my fuel leak, or whatever is creating that gas smell.  The gas cap doesn't appear to be making a good seal, and when I checked the fuel sender on the tank (had the seats out anyway) the existing o-ring is the wrong size and appears ineffective.

So I went to my local parts place and got replacements.  No leaks at all and that gasoline smell is gone.  Plus the engine runs just a tad smoother, probably because there is pressure in the tank and not suction from the fuel pump.

I think I've figured out  why there is no air coming out of the heater.  The switches (off vs heat vs defrost) work off vacuum.  I found what appears to be a vacuum hose not connected to anything under the hood.  Another future project...

The engine seems to run a bit hot.  After yesterday's short ride (15 minutes) I moved the license plate from the grille to the front bumber and the heat coming off the hood / grille was almost unbearable.  It was a cool day here yesterday, high only 78.  The coolant is circulating because the radiator and hoses are hot.  Probably okay until next Spring, but something to look into.  The temp gauge doesn't work, always says COLD, but that should be an easy fix once I figure out the wires.  The hot engine may explain why it feels so hot behind the firewall.

In the meantime...she's running and she's on the road.

Thanks for looking...

Brakes are better

I don't like working on brakes.  I must admit it is a bit satisfying once done, knowing the work was done right and all, but before and during the process I just don't like brake work.

So since she needed an oil change (well, just to make me feel better) I took her to my local mechanic (he gets all the really hard stuff) and asked him to check the brakes, change the oil, check for leaks (okay, I know of a couple) and look at the steering.  Essentially a good once-over.

He brings in his specialist who only works 3 days a week and only works on old vehicles.  His "old school" guy.  Brakes were way out of adjustment, all the way around.  E-brake not working at all, fluids low all around, leaks in main bearing seal and around transmission.  I'd need to get some parts (he doesn't source antique parts) and most of what he was telling me went right over my head.

Good news in the near term is that the brakes work real well, no pulling and based on adjustments everything feels much better.

That means I can now get her tagged and titled!

Thanks for looking...

So what have I gotten myself into?!

August, 2012

After getting the girl home I had to assess what I've got before just jumping in and driving.  Some Jeepers do just that and while many are just fine some get themselves into some trouble.

My uncle always just jumped in, pumped the gas and pulled the choke.  Started her up and then went.  But then again he'd had 40 years with her and knew every wheeze and squeak she had.

I also had to get her titled and tagged so I could take her to a shop and have some assessment done...you know, things like brakes and steering.  The good news is she's technically historic, or antique, and therefore doesn't require emissions testing.  No way she'd pass that!

After a good check of fluids (she WAS driven onto and off of the trailer) I took her for an easy drive around the 'hood.  Brakes are wonky.  Pulls to the left...then the right...then back left again.  A hard stomp on them and she's all over the place.

Wanders about on straight roads.  The steering needs some attention.

Noisy around the transmission and/or transfer case.  Vibrates a bit as well.

Fuel gauge doesn't work, nor does the temp gauge.  I've read this is a common problem.  Lots of orange overspray as well.  Lights sort of work...turn signals don't and neither do the emergency flashers.  Brake lights work.

And the gas smell.  Obviously a leak somewhere.

Under the hood...the battery tray is barely together.  Okay, it's not.  I'm just kidding myself.

No mirrors on outside...let's see, according to the factory photo I have here, she should have just the one on the left, and it's rectangular, not round (pre-1968) or square (post 1973).

You know, I'll just pretend that's the Old Girl coming off the production line...

Cosmetics:  Look at this door handle:

That's an easy fix.

Seats are falling apart.  The seat covers are falling apart as well, actually they may be only thing holding seat cushions together...have to find new seats if I'm going to drive her.

No grab handle on the dash.  Just the holes.

The rear cross member (or is that a bumper?) is rusting away.  Lots of holes that aren't supposed to be there.  The draw bar is starting to come apart due to rust (and there's lots of paint on the rust).

Note there isn't a "4 wheel drive" logo on the tailgate.  Where will I get the stencil?

Well, time to start putting things together, and finding a reputable place to buy parts.

The FUN begins!

Thanks for looking...

The Old Girl is mine!

7th August, 2012

She was originally my uncle's Jeep.  He got her back in 1970 when he was quite young as something to have fun with.  She likely never went more than 50 miles from central Maine where he lives.  

She DID spent lots of time in bogs, along logging trails and generally "in the woods".  I understand a few empty beer cans have been known to rattle around behind those seats in the cargo area!

My brother and I both have connections to her but during very different times.  I've driven her a bit (maybe my Grandfather's red one more?) and so has my brother.  Seven or more years apart given we both have memories of doing that during our high school years and that's the difference in age...

The running joke between us, and the whole family participated, was which one of us would get it and how we'd determine that: arm wresting, sprints, or cards it didn't matter because in the end it came down to who had the time and inclination to treat her right.

So on the 7th of August, after we agreed I could have it and my uncle and I agreed on the price I jumped in the truck and got up to Maine before either one changed their minds!  Talk about exciting; I looked forward to the trip all the way up and then driving her when I got home.  While my uncle was quite at home jumping in and just going, I wanted a good look over her because some things about her just weren't right.  So I didn't drive her while in Maine but waited until I got her home.

That's when all the "fun" started.

Thanks for looking...