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CJ and Scrambler (1945 - 1986) Technical forum for the Jeep CJ.

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  #16  
Old September 25th, 2020, 15:53
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Re: 1976 CJ5 Project

Spent most of the day messing with the CJ. Got the pulley and reservoir on the PS pump after painting it.



Got both diff's drained and refilled with new gear oil. The old stuff was pretty disgusting and the front diff had obvious water contamination but luckily the gears were spared. The rear diff is leaking from the pinion seal already so I get to drain that again and replace that seal the diff cover is also leaking a little bit, ordered a new rubber seal for that. Yay. Front diff sealed up fine.



Replaced the rear rubber brake line from the frame to the axle. Pretty sure it was the original. Need to do the front's eventually but they'll be easy to do even with the tub on the frame.



Got a little carried away with my big press while changing U-joints and busted the ear off of the slip yoke of the rear driveshaft. That was an 80 dollar mistake. More like 100 after I get the shaft rebalanced.



The front drive shaft has a ton of play but the splines on the drive shaft look fine so going to test the new slip yoke on it and see if I can salvage the shaft with a new 80 dollar slipyoke vs 250-300 for a whole new front drive shaft.



Painted a few odds and ends here and there but getting closer to having the driveline/frame wrapped up and starting on the body work on the tub.



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2004 Suzuki DL650 VStrom/1978 Suzuki GS1000E/2003 Yamaha TW200
1982 Suzuki GS850G (barnfind project)
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  #17  
Old September 25th, 2020, 20:52
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Re: 1976 CJ5 Project

Bummer on that ear. Those things happen.
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  #18  
Old September 26th, 2020, 19:51
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1976 CJ5 Project

Indeed. Im not sweating it but the front driveshaft is shot. The splines are worn to a knife point.on the ends and all of the blue coating is gone. Going to have to go new on that one. Probably Tom Woods.


Resealed the steering gearbox and got the transfercase as far as it will go without the output assembly shims I need. Also inspected the front drive shaft and its not going to be salvagable.



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1982 Suzuki GS850G (barnfind project)
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  #19  
Old September 29th, 2020, 19:55
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1976 CJ5 Project

Painted some more odds and ends

Got the Tcase finished with exception of the shift shaft seals, all I needed was the thinnest shim in the new pack of shims to get within spec ha. Amazon dropped the ball on the seals and lost them so had to reorder.

Rear driveshaft rebuilt with new slip yoke

Replaced Valve Cover gaskets. Engine is a little sludgy. More than I would like but I'm going to ride it till it won't go anymore. Compression is still alright.

Got the clutch linkage rebuilt

Steering gearbox mounted back on the frame

Remounted the headers

Reconnected the exhaust

Replaced the ancient spark plugs

Remounted the carburetor

Started trying to reverse the hack job one of the previous owners did with all the emissions gear.

Put the sending unit and new seal on to the gas tank

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  #20  
Old October 2nd, 2020, 08:00
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Re: 1976 CJ5 Project

Yesterday I started cutting the rot out of the body and got the passenger side floor panel cut to size and tacked in place. And painted one side of the tailgate.



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  #21  
Old October 6th, 2020, 18:31
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1976 CJ5 Project

Got the floorboards and patches stitch welded in and sealed. One set of patches i made a little oversized and went with a gauge heavier steel and did a full seam weld on both sides because thats where the seatbelts will be bolting through.

Hoping to get the underside and maybe the inside of the tub primered and painted tomorrow. Then try my hand at Bondo for the first time on two patches i did on the side of the tub.

Goal is to squeeze another 3 to 5 years out of the current tub then drop a new one on possibly





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  #22  
Old October 7th, 2020, 19:55
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1976 CJ5 Project

Burned up a lot of paint and primer today doing the underside and inside of the tub.





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  #23  
Old October 9th, 2020, 21:37
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Re: 1976 CJ5 Project

Tore the AMC 20 rear axle down on the CJ. One of the previous owners apparently did me a favor and put one piece axles in it at some point. Got a good chunk of the work done. Got the carrier bearings removed and new ones put on along with the ring gear. Got the old pinion races out. Tomorrow I will start going back the other way. Not looking forward to setting up the pinion depth. The original setup used a large shim under the bearing race. All of the rebuild kits come with shims that go under bearing cone. And none of them are of similar size to the original shim.















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  #24  
Old October 13th, 2020, 07:00
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Re: 1976 CJ5 Project

Finished up the AMC20. That was my first gearset install. That was my last big obstacle with the frame and drivetrain going to drop the tcase and driveshafts in tomorrow then I'm down to some bodywork and paint. I can kind of see the light at the end of this tunnel.
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  #25  
Old October 18th, 2020, 06:32
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1976 CJ5 Project

Rest of the drive train is now in.

Got the PS pump and hoses hooked up.

One of the previous owners replaced the low pressure line with a section of airhose it looks like.

Got the fuel tank backin as well with new hardware and Rubber lines.

Today im going to try to "unf%$k" the emissisons lines and routing. Unfortunately many of the factory emissions parts are MIA from the previous owners.







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  #26  
Old October 18th, 2020, 15:01
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1976 CJ5 Project

Some light work today. Got the dash panel mostly put back together, got a few of.the emission lines sorted out but not all and replaced the damaged tie rod on the drag link.

Wouldn't mind finding a repro of the vin tag that was on the dash.







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  #27  
Old October 18th, 2020, 15:10
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Re: 1976 CJ5 Project

Looks like all your hard work is starting to pay off.
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  #28  
Old October 24th, 2020, 19:51
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1976 CJ5 Project

Got the tub the rest of the way painted. It's not the greatest. Its a "100 foot" paint job. I tried my hand at bondo for the first time.....you can tell 🤣



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  #29  
Old October 25th, 2020, 08:28
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Re: 1976 CJ5 Project

Might not be perfect body work, but I am sure you have given that tub a new lease on life.
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  #30  
Old November 2nd, 2020, 02:47
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1976 CJ5 Project

Front brakes rebuilt and tub back on.







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