JD Cruiser's 1981 BJ42 Body Repair & Restoration (1 Viewer)

[Jdc1]

This will help with the drag link:

Amazon.com: Stanley Proto J5444A 1/2-Inch Drive Socket, Drag Link 3/4-Inch: Home Improvement

 

[JDCruiser]

jdc1, thanks for the tip... didn't realize they actually made a tool for removing the drag link nut.

 

[JDCruiser]

Tie Rod Removal:
I removed the remainder of the tie rods without any issue. Used a pickle fork set that I got at princess auto, found the attachment for the air hammer to be the most effective. It will damage the boots but all of my tie rods will be replaced anyway. Here are some pics of the removal...

 

[Jdc1]

jdc1, thanks for the tip... didn't realize they actually made a tool for removing the drag link nut.

I spent at least 2 hours on mine, got frustrated and ordered it. As soon as it arrived, i had it off in 30 seconds. My second build will go alot quicker, from lessons learned and tools aquired. Happy 2017.

 

[JDCruiser]

Thanks, will definitely get an order in! Happy 2017!!

 

[JDCruiser]

Steering Damper & Center Arm Removal
Next up was removal of the steering damper and center arm along with what I call the pivot can (not sure what the official name is for but I am sure you know what I mean when I say pivot can)... Center arm came off with no sweat at all using the puller.

 

[JDCruiser]

Front Strut Removal
With the steering linkage removed, next up was start the removal process of the front suspension, leaf springs and axle. This begins with the removal of the front struts. They came of very easy, will be replaced with as part of the OME suspension system.

 

[JDCruiser]

Front Axle Removal
I made an attempt at removing the shackle pins from the leaf spring bushings, however, they were really seized in there so I had to revert to cutting out the springs near the hangers. I will then have to remove the bushings and shackle pins by cutting out the cores and beating them out with a punch. Will do that at a later day with final frame prep. Here are some pics of me cutting out the front axle.

 

[JDCruiser]

Leaf Spring Removal from FR Axle
I then needed to remove the leaf springs from the front axle. I tried removing the U bolt nuts with my air impact wrench but none of them budged so I had to cut the U bolts off. I took the small 3" air cut off tool to them so that I was sure to not scarf or damage the axle. It worked well, similar to the rear axle. Here are some pics

 

[JDCruiser]

Front Axle Stand Build
I wanted to get some mobile stands for the axle so that I have the flexibility to move them around as needed in my garage due to the rebuild space constraints. I started trying to some mobile ones for sale but couldn't really find any to my liking that were affordable. So I went to princess auto (kinda like Harbor Freight for those of you from the US) and got a couple of 600lb wooden moving dollies. I then reinforced them with a couple of 2x4's and attached some 2x6's with some metal angle brackets as the uprights. I cut a V in the top of the 2x6"s so that Axle housing wants to sit on top. When I first loaded the axle to it, I wasn't happy with how much it seemed to want to rotate, especially if the hubs rotated reward in the same direction as the diff housing. So I attached a 2x4 to the back side of the dolly as a counter support. I then strapped the axle to the uprights using roundall. Stand cost me about $30, with the dollies costing $20 of that. Here are some pics of it.

 

[78Landcruiser]

Thank you for saving another 40!

Keep up the great work!

 

[JDCruiser]

Front Body Mount Washer Removal
I didn't realize until when I tried to remove what I thought was just residual body mount that the Front mounts have a pot welded washer on them. I figure it is there to finalize the FR mount hole taking it from a rough cast shape to final OD with a bushing in it. I am a bit puzzled because the replacement mount kit that I bought doesn't have that small washer bushing insert, so not sure if the shouldered washer is needed. If anyone reading this is familiar with the FR body mount structure feel free to chime in and educate me on what I replace this with, is the shouldered washer that was spot welded to the outrigger support bracket. Here are some pics of the removal of the Passenger side, I used t a spot weld cutter to remove it.

 

[JDCruiser]

I then removed the FR Body Mount Welded washer on the Driver's side which had the same structure.
Here are some pics.

 

[JDCruiser]

Front Bumper Removal
I have been struggling with removing the 2 front leaf spring eyes so I figured I would take a break from it before I hurt the frame or myself and work on the FR bumper removal, that was a task that is needed to be done as part of the frame strip down and figured it would be an easy one. It was easy, I had soaked the nuts in PB plaster from about a week ago which softened them up. It came off real nice... Here are some pics....

 

[JDCruiser]

Front Bumper Top Brackets Removal
Next up for removal were the top support bracket plates which tie the front bumper into the main frame rails. They came out really nice too. here are some pics.

 

[JDCruiser]

I then removed the Driver side, same structure as Passenger side but had the tow hook up on top. Here are some pics...

 

[caper]

Hard at er now Bye , keep er goin !!!!!!!!!!!!

 

[-MaTTi-]

How is this nowadays?

 

[-MaTTi-]

Ready by now?

 

[waiting for time]

Last seen on mud feb. 13 2018.