All 4 gears (1 Viewer)

[CruisinTiger]

Thanks to Marshall, JP, and Rick....yesterday we had a great hamom.....after about 6 years of running without 2nd gear we swapped in a new set of guts in the 60....it is great having 4 gears again....Rick replaced his busting on the fj and as with any great hamom he had to do some mafia fabbing after the bolt shaft was destroyed in the removal process....a few hours later and a piece of pipe and a PBR can and the front end was done.....what a great day!

 

[BMThiker]

I'll post up more pics later today, but here are a couple of the PBR can fix. It was a good time and we had some awesome BBQ too.

I worked on my IFS lower control arms most of the day. The bushings were shot and the rubber was starting to tear/separate. The first one came off with only a minor struggle. It took a little propane (and a lot of banging) to coax the bushing from the arm. The second arm was a bit more onerous since the steel sleeve of the alignment bushing had siezed inside the rubber bushing. I used Chuck's sawzall to cut it out and then Marshall and I went to Lowe's to scavenge for some replacement steel - anything to replace the steel sleeve would at least get me home.

We landed on a piece of black steel plumbing pipe. The outer diameter was pretty close, but the inner diameter was too small. I picked up a 9/16" drill bit to open up the inner diameter. Got back to Chuck's and used his drill press to bore out the pipe...came pretty close to the diameter of the bolt, but a little loose.

This is where the PBR cans in handy (and we had a few empties laying around). Using a pair of scissors I cut off the tops and bottoms so that I had flat sections of the cans.

Shimmed the bolt and slid it inside the newly bored pipe. Added a couple cans worth of aluminum shims to the outside of the steel sleeve and the whole thing got crammed into the rubber bushing, once the lower arm was in place.

My alignment was wacked out, but it drove home at 75mph with no wobble at all.