fixing the XJ with a toothpick

 

Ocotillo clinging to the Carrizo

 

Little Sancho

 

Joshua Trees in Mojave

 

Providence

 

Little Cowhole

 

Emily welding

 

Mojave sunset

Black Mountain Lookout

 

My girls are finally back at home. I am very happy.

 

TJ: Yet another problem that revealed itself when doing the re-gearing: the universal joint between the driveshaft and the rear axle needed to be replaced. It was very difficult to get out of the driveshaft. I had to use an air-hammer to push the cap out of the yoke.

 

TJ: The upper front control arm joints required me to remove one of the mounts and replace it with a new part on the axle. This is the most extreme modification I have done on any of my trucks. I was never comfortable cutting parts that would be very expensive to replace if I made a mistake.

 

TJ Re-gear Project: I had to make set-up bearings that I could easily remove from the pinion and carrier while finding the proper shim packs. I did this by turning the bearings on the lathe while rubbing with 80-grit sandpaper.

 

TJ: When taking the front axle out to put the new gears in, I had to cut out the lower control arms because the bolts were seized in the bushings. I hate bushings because of all the trouble I have had with them on other vehicles. I wanted to try these rebuildable joints and make adjustable control arms as replacements.

 

TJ Re-gear Project: Another of the problems we had was the spider gears in the Model 35 differential were worn and damaged. We cannot reuse them.

 

TJ Re-gear Project: This is a pattern on the coast side. They can be difficult to interpret. Whatever shape it is, it needs to be in the middle of the gear.

 

TJ Re-gear Project: This is my first contact pattern on the Model 35 differential. It is almost perfect and I was very pleased I got it. Setting driveline gears can be difficult and stressful. This first little success gave me a lot of confidence.

 

TJ Re-gear Project: Something I did not realize when I started this project: Yukon Gear does not make their ring gears with 7/16" bolts as my stock Model 35 axle. They expected me to buy (at $10 each) little sleeves to make up the difference in size with my carrier. I made these on my lathe.

 

TJ Re-gear Project: We have been having trouble with the gear kit we have bought from Yukon. I was not sure if the specification for my Dana 30 was wrong, or Yukon put the wrong bearing in the master rebuild kit, or Yukon gave me the wrong pinion. I took my pinion out to verify the size. 

The size I measured on my old pinion matched the specification and the new pinion. Yukon put the wrong bearing in the master rebuild kit.

 

TJ: Dana 30 water intrusion from all of our water crossings (need new seals)

 

TJ Project: front bumper before painting

 

TJ Project: front bumper

 

Trooper Rock Crawler: heater hoses

 

Trooper Rock Crawler: computers

 

Trooper Rock Crawler: removing dash

 

Trooper Rock Crawler: removing seats

TJ: transmission fluid change

 

better truck lift

 

Nana sneaking up on Vanessa

 

good plug for giant hole

 

giant hole in my tire

 

Storm over High Sierra

 

Afton Canyon

 

ZJ project: original radiator cap still works (amazing)

 

XJ: missing headliner

 

XJ: the only transmission fluid change that doesn't make me cry

 

ZJ project: coolant flush

 

hot work area

 

ZJ project: engine inspection

 

XJ paint project: rear door weatherstripping

 

XJ project: headliner replacement

 

Inyo Mountains from Saline Valley

 

Eureka Dunes

 

storm over San Gorgonio

 

XJ paint project: rebuilding rear door lock mechanisms

 

XJ paint project: cleaning rear door hardware

 

XJ painting project: rear door trim panel cleaning

 

bee inspecting the new Jeep

 

near Shasta

 

XJ: new restraining bracket insulator