Razorback Restoration's 67/68 88" Rebirth

Over the past fortnight we have managed to strip the body off the chassis so we could have a real good look at it.

Unfortunately, the results are not too good. The rear of the chassis is rotted out from forward of the spring hangers. There's bad rust in the front section of the chassis. The A pillars of the firewall are rotten, and the radiator support bracket isn't to good.

We are hoping that we can rely on the simplicity of the manufacture so that we can make replacement parts for those which are rusted out.

On the bright side, we have hardly found a nut or screw that could not be undone easily. We did grind a couple of bolts off to save time.

The next task is to lift the motor and gearbox out and whip off the axles and suspension.

Here are some pix:



Old Man Emu

Seems my partners have deserted the ship, leaving me to pull things apart and get the accumulated muck off so we can start splashing some paint about.

I've stripped everything off the chassis except for the Steering Relay Box. I've been told that it is a real bitch to get out.

I've undone the two bolts which go through the brackets on top of the chassis cross rail, and bent the brackets a little. I've taken off the steering rod arm, and everything that bolts into the lower end of the relay shaft housing. I've squirted some WD40 down the sides, and driven wedges under the wings where the two bolts I mentioned above go through the housing.

I can't twist the housing because the brackets are in the way, and I feel that if I get the housing above the brackets, it's going to be out anyway. As a last resort I could cut off the brackets and weld them back on later.

I'm a bit scared to go bashing on the transfer shaft for fear of breaking something. Please advise if that's the way to go.

Old Man Emu

Please tell me there is an easy way

Quote:

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Originally Posted by Old Man Emu

Seems my partners have deserted the ship, leaving me to pull things apart and get the accumulated muck off so we can start splashing some paint about.

I've stripped everything off the chassis except for the Steering Relay Box. I've been told that it is a real bitch to get out.

I've undone the two bolts which go through the brackets on top of the chassis cross rail, and bent the brackets a little. I've taken off the steering rod arm, and everything that bolts into the lower end of the relay shaft housing. I've squirted some WD40 down the sides, and driven wedges under the wings where the two bolts I mentioned above go through the housing.

I can't twist the housing because the brackets are in the way, and I feel that if I get the housing above the brackets, it's going to be out anyway. As a last resort I could cut off the brackets and weld them back on later.

I'm a bit scared to go bashing on the transfer shaft for fear of breaking something. Please advise if that's the way to go.

Old Man Emu

Please tell me there is an easy way

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Good luck... I used a really big hammer to drive mine up, but burred over the end of the shaft in the process. I have seen other cut a section from the front crossmember. I would suggest lots of lanox... and maybe a little prayer :P

I've got a series II chassis that's in pretty good nick (rear X member only Rust), that needs a new home.
P.S The steering relay came out easliy with a jack :)

Yes, I have been thinking about using an hydraulic 10 tonne jack. The picture shows the method I think I might use:

Old Man Emu

A few years back I converted an 88 chassis into a trailer. I stripped everything off it, and spent about a week trying everything I could think of to get the steering relay off. It still has the steering relay in it!

John

It seems that the steering relay assembly could be the only design fault in the whole show.

OME

OK. Looks like it is stuck like fundament to the blanket.

As the steering relay assembly is the only thing left on the chassis. Should I undo all the bolts, top and bottom and service the unit, leaving the housing where it is stuck in the chassis?

The assy has to be filled with lubricant. Is this oil, or grease? If it is grease, should I drill and tap a hole in the side of the assy and fit a grease nipple?

What is the grade of lubricant to use?

Thanks

OME

Quote:

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Originally Posted by Old Man Emu

OK. Looks like it is stuck like fundament to the blanket.

As the steering relay assembly is the only thing left on the chassis. Should I undo all the bolts, top and bottom and service the unit, leaving the housing where it is stuck in the chassis?

The assy has to be filled with lubricant. Is this oil, or grease? If it is grease, should I drill and tap a hole in the side of the assy and fit a grease nipple?

What is the grade of lubricant to use?

Thanks

OME

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I would be inclined to leave it there and overhaul it in situ. However, either do a search on here for how to do this, or read the manual. Unwary disassembly can cause serious injury from the spring inside.

It should be filled with EP-90.

John

Yeah. I'm aware of the 40 lb tension on the spring. I'll be careful!

OME