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Spent some time filling holes in the front of my frame. Had 7 random holes top and bottom. One of the top and one of the bottom holes were for the front bumper. I’m using frame extensions, so filling holes gave me some welding practice. Need to grind them down tomorrow. Small steps.

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Weather is about to get too cold to paint. Chassis Saver needs to be applied at 50* or higher. Pushed the limits last couple of days. Applied at 58 for the silver and 51-64 on the black. Wood stove felt pretty good and the tunes were on. Getting close to reassembly of rolling chassis.
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Making some progress. First time axles have been under frame since 2011. Was trying to finish the knuckle rebuild today. Put the new piñon seal in and started tightening it up. Was tightening the stake nut, and couldn’t get it to pull the flange all the way in. By this time, I could barely turn the flange. Backed everything off, tried again several times. Same end point, too tight to turn, even before torqued. Decided to pull the third member out. On the bench, everything looks okay, except there is a lot of axle grease on the gears. Could this be just stiff enough to cause drag throughout ? I plan on soaking the third in a bucket of diesel to get the grease out. Anything else I might need to look at? Frustrating to think the afternoon is going one way, just to get side tracked.
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This is the original third. Only thing new is the seal and nut. Did the same on the rear, and it turns freely. The front end did fall off of the jack stands and allowed the pinion gear to fall inwards. I was able to lift and rotate it into the ring gear without any problem. The bearing behind the oil slinger cover looks clean and no pitting. I do not remember turning it before disassembly, so this might be an old issue?
 
My thoughts as well. Just never really messed with setting up third members. I do have a couple of extra 4:10’s in the ‘69 that spin freely. Didn’t really want to go down that road. Maybe this was the reason someone quit driving it?
 
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Solid spacer. I replaced pinion seals on several third members over the years. This is a first for me.
 
You 100% sure the seal has the correct ID and not binding on the pinion?
 
You 100% sure the seal has the correct ID and not binding on the pinion?
The seal is completely removed at this point. Third member on the workbench. With the seal out, and just tightening the flange ,it binds. Considering it wasn’t completely disassembled, not sure what happened. At this point, I’m really thinking of pulling another third member and using it. With only a couple of hours at a time to work, I just want to keep moving forward. Rolling chassis by Christmas is my goal.
 
Solid spacer. I replaced pinion seals on several third members over the years. This is a first for me.

Lots of times you can replace the seal and re-torque the pinion flange and you are good to go.

If the shims are no longer intact, as mine were:

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then applying the same torque spec will now be wildly inappropriate.

Some fun reading here: Third Member Swap - DENIED!!!
 
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