Georgine. The poster child for ongoing maintenance. 1999

[Comet]

Heater T's and hoses are a must replace item. Thank you to Joey at Witt's End @NLXTACY for the complete kit.

 

[Comet]

Logan's Run 2019 Camp site night one. BANG! Limped out of the woods the the Outpost for an 8 hour wait on a tow three hours from home. Popped everything out of the front after draining the front third member gear oil to find large chunks of metal. Destroyed one gear, damaged one, dented another.

 

[Comet]

Main carnage. Third member cleaned up and ready to go back in. The gears and what not before putting back together. Screwed up some threads, filed them perfectly so they would go into the differential housing. Nail biter for sure......

Last picture is everything back together. I used the side burner on my grill to get the ring gear warm and then finished it off with some MAPP gas right before I set it in place on the differential. It kept me up the night before just thinking about what I would need to do in what order. Note to self: Don't loose sleep over such a simple process.

 

[erse]

Love all of the pics, especially your purpose built tire transport vehicle
Quick question on the ARB air if I may, do you have a pic of how it was wired/fused? Struggling with mine right now and trying to figure out which part of the spaghetti to start on.

 

[Comet]

I just left the rats nest in the engine bay. Before wiring up I would run it through the fire wall. I think there are connections I would put on after. Wired direct to the second battery. I will get better pics tonight.

 

[roadstr6]

Here are a some pics of Travis trying hard to forget about that sickening "BANG!" we all heard in the front of the truck as he and Georgine were mounting the infamous Poser Rock:

 

[Comet]

FYI Dave @roadstr6 , I was WAY HIGHER UP the rock face when it gave up on me. Ha Ha. Pictures of the carnage to come after the rebuild. Thanks to @1428Mike I made it home.

 

[roadstr6]

I took Nathan and his buddies out there a couple of years ago to drive their RC's and this truck drove all the way over that rock while we just stood there in total amazement.

 

[SAH]

This is an awesome thread with some presumably dry humor. Tell me more about the bang.... Torsion bar related?

 

[Comet]

The bang was the internal gears of the front third member going tits up. I have updated the pictures above to show the beautifully destroyed gears. It's funny, for such a well maintained rig prior to my ownership, there is sure a lot worn out on the old gal. Replacing spider gears, lower ball joints, seals, and gaskets. Lots of brake cleaner and paper towels were used in producing this thread. Thank you to Kurt and Bryce and Cruiser Outfitters for the knowledge and parts to keep moving forward.

 

[Green Hell Mustang]

Here are a some pics of Travis trying hard to forget about that sickening "BANG!" we all heard in the front of the truck as he and Georgine were mounting the infamous Poser Rock:

The truck said "no."

 

[Comet]

Georgina definitely said no. She also said no every 30-40 feet with a loud thump. Drove out under her own power to the Outpost and the tow home took all day.

 

[AlpineAccess]

Did you end up doing the upper ball joints boots? Looks like you've got a torn one.

Great thread - looks like you've had a lot of fun with it.

How did replacing the ring go?

 

[Comet]

If the upper boot was torn, I missed it. I did put a new clamp (can’t remember technical term) on one of them. Now I gotta go back and check. Good eye.

Truck has been a blast and flawless. Until I go and break stuff.

The ring was a no brainer. I was truly stressed about it and did loose sleep. It popped right on and I was able to match it back to its original position.

 

[Comet]

Radiator. Old one was leaking from the bottom.

 

[Comet]

Yesterday was a gloriously uneventful day in our household. Georgine is now my sole responsibility. I will drive her, I will hug her, I will change her fluids, and I will call her Georgine. She has been passed down the line after my loving and very understandable bride acquired a 2003 GX470 (I was very motivated after seeing and briefly driving @landwagon GX470 this past winter). The GX470 is Rufus approved. And we are now going to see a massive spike in the cost of fuel because two Toyota v8’s are obviously better than one.

Issues to address now that she is mine are to reinstall the Slee second battery tray, reinstall the RedArc battery isolator, reinstall the ARB twin compressor, remove the roof rack (plug the holes), remove as many seats as I possibly can, remove faded wood trim, build a sleeping platform/chuck box that accommodates my work pack out and a refrigerator, mitigate or eliminate the driveline “clunk” from reverse to drive, lift the front end just a tad to correct stink bug to proper rake stance, and tighten up every bolt I can get my wrench on. Good times to come.

 

[Comet]

I read, I surf, I research, I read, and surf some more. Ah heck, I guess it’s time to keep things moving forward. RedArc back in, Slee 2nd battery tray back in, Second battery back in, Compressor back in and switch dash mounted. A pile of switches, circuit breakers, and 12 volt solutions I didn’t even know I needed are still in a box though. Running the refrigerator off battery clamps and an adapter.

 

[Comet]

So the “bang” from park to reverse to drive to reverse to park has become progressively worse through the years. I understand that there is a lot of slop in the drive line and things wear out. With that in mind, I contacted Cruiser Outfitters yet again. Yet again they were super helpful and provided me with everything I need to address every possible scenario with the front suspension. The front hub drive flanges were the easiest repair I have done to date. I didn’t realize it could be done with the tires still on the truck until I read. This forty minute excursion into #2 Red and Tacky revealed worn hub flanges because the before and after is totally unbelievable.

 

[Comet]

The hub flange took the bite out of the “bang” but it was still there. Next up was the three bushings on the front third member. As you have seen in previous posts, this third member has already been out of the truck once under my management. Folly and fun go hand in hand.....I break stuff.

The driver side was super easy and a great confidence booster. The front bushing sleeve has been the Bain of others existence so I went ahead and persuaded the snot out of it with an impact hammer. Took three minutes to get the sleeve out. Joy. The new sleeve was not so understanding. A few hours in the freezer to cool off allowed 80% penetration. The rest came from an air hammer, the floor jack, and some friendly words spewed in the general direction of the truck.

 

[Comet]

The bushing assembly on the drive shaft was a complete and utter disappointment to all shade tree mechanics like me. The 19mm 14x1.5 bolts all came out easy enough but when reinstalling I somehow cross threaded both of the blind holes. No one in town has the 14x1.5 tap and die set. Even the cheap chinesium was off the shelf in my town. Drive around in my sons 1988 Trooper for a few hours and happen upon yet another Harbor Freight in a neighboring town. YEAH! Not one, not two, but three metric sets are sitting on these shelves. BTW, computer in my town said there weren’t any to be had in a 100 miles. Head home and all went well after. Bang is nonexistent except for the usual driveline lash. I count this as a win.