Ewan's 79 CJ-5 restoration project

Transmission rebuild on hold again, had to order another part. 1st gear/reverse synchro assembly gears are chewed up pretty bad, ordered a new set.

 

Fuel lines installed and brakes almost done. Rear line looks pretty ugly, I'll shape it to fit better once I get the rear soft line installed and see how much slack I have to hide away.



I'm not using the stock carter carburetor so I purchased a piece of poly-armour steel line to run from the pump outlet to the fuel filter. 5/16" with 1/2-20 inverted flare fitting, $4.50 at the store. It bends really easily and seems quite stout, I'm almost tempted to order a coil of it and replace the main fuel line with it.

 

All brake lines installed and hooked up, minus the front hoses. I can't find my banjo bolts, I probably threw them out. That rear feeder line is still an ugly mess but you won't be able to see it once the tub goes back on.

 

Reverse idler gear came in the mail today, started to put the transmission back together. Still waiting on my 1st / reverse gear synchronizer assembly which should arrive later this afternoon.

 

Almost done, had to take a break since I was getting really ****ed off. This really is a simple transmission and easy rebuild like many others have stated, however I kept having terrible luck. Stupid needle bearings kept coming out and thrust washers wouldn't stay in place. Went through almost a whole container of vaseline and still had problems.

 

Transmission rebuild complete minus shifter.

 

Transmission installed however I have another problem. For some strange reason my transmission sits about 1 1/2" inches forward of my transmission mount. I'm thinking it has something to do with the problems I had with my skid plate lining up with the frame bolt holes. At this point, I'm just going to fabricate an adapter out of some spare 3/16" steel plate I have laying around.

 

Adapter plate test fitment minus stabilizer bar / plate support, got it right on first try which was a nice change from the usual cut, cut, cut, drill, drill, drill. Waiting on stabilizer bushings, ordered some poly ones.

 

Tore apart the transfer case tonight, all the internals looking pretty good. No chips or wear patterns on any of the gears, bearings & races look good. No wear patterns or markings that I can see on the intermediate shaft. Since the bearings are Timken, I assume the transfer case was rebuilt at one point. Ordering a new gasket / seal kit and going to button everything back up after a good cleaning.

 

Working on the transfer case today which has been slow. It doesn't help when you're sick and the garage is 30 degrees. I started to assemble, put the shift rods in and realized I forgot to put the poppet balls and springs in.

 

Finished rebuilding the transfer case, waiting on the paint to dry so I can mate it back up to the trans.

 

Looks great !! you sure have a bunch of projects!

 

That is what the wife keeps saying. At least the Jeep is pretty close to done minus body & paint work. The Lotus replica is probably another year off. It is nearing "roller" state however I have no room for it until the Jeep tub is repaired and back on the frame.

 

Transfer case installed, time to work on the drive shafts. I also have one hell of a mess to clean up, garage kind of exploded.

 

I attempted to install the rear drive shaft tonight, just to find out it is almost 2 inches too short. There has to be frame differences between my original 79 and this 80. My transmission sits about 2 inches too far forward which was remedied with an adapter plate, but it appears I now need a new rear shaft.

 

And a big bottle of tylenol

 

I found another shaft on ebay that will fit, only $60. I should be able to sell my driveshaft, it has US made u-joints and a fresh coat of paint.

 

Tub back on today for fitment test and gave me a chance to clean up the other side of the garage. Nice to see the tub back on, even if it is in poor shape.

 

A Lotus, Triumph, and Jeep, you are a glutton for punishment aren't you?

 

Nah, just a sucker for unique vehicles. I actually sold the Triumph, ended up getting my money back. I wasn't in it very much, $500 and some parts for tuneup. I need a bigger place, hoping to move next year into the county and find a place with a shop. I also have 67 Firebird that is taking up space, storing it for my buddy who shipped overseas.