Time for upgrade...

[Mtbcoach]

The wife and I went down to the OBX for the club's annual event, Spring Tide Ride. On the way home, we hear a sound that became increasingly bothersome as we were leaving the OBX. I stopped to investigate, following the sound through the trailer, isolating it to the FJC.

After too much mental masturbation, I crawled around to see what I could see and low and behold, it became quite clear what the problem is.

The rear output shaft of the Inchworm Lefty is clearly leaking, and, as the video shows, has plenty of play in the output shaft bearing. Fortunately, Marlin had a special on their oversized CroMo 30 spline output shafts (both front and rear output) so they are on the way along with a gasket kit.

So, I guess I'll be taking my Inchworm out, going through it and installing some beefy output shafts. I'll post up the progress as I go along for those interested...

Pic of the output shaft and nice spray pattern...

Pic of the rear diff plug and associated "paste", nothing out of the ordinary here...

Video of the slop in the rear output shaft...



Next up, dropping the skids, exhaust and interior pieces to remove the Inchworm before the rebuild parts get here...

 

[FJNewb]

Might also want to consider upgrading the front output to a 30spline as well while you are at it.

Looks like a fun project!

 

[Mtbcoach]

I clarified the first post where I put "shafts", I presumed all would know that I'm doing both front and rear output shafts. Marlin had a special, when buying both, got the front output shaft 50% off. How could I resist...

 

[1911]

At least it happened before the Rubithon and you have time to fix it Jerry. Though it's not much fun to pull and replace it - I've done mine enough times that I'm tired of it, even if it does get faster every time! Best wishes for the repair; if I was closer I'd help you do it.

 

[Capt Sensible]

That sucks. At least you were able to diagnose the problem easily. Good luck.

 

[Mtbcoach]

Stuff happens, its the price one pays for playing. I never did the initial install so its about time I got intimate with my Inchworm...

 

[Capt Sensible]

yep. unfortunately. i just hate when something breaks for the "awww s***" factor. my wallet hates it for the same reason.

 

[Mtbcoach]

Trust me, I'm not happy about it but try to look at this as an important upgrade opportunity. Or, maybe its an excuse to upgrade, at least that;s what my lovely spouse thinks...

 

[1911]

Jerry, if you don't have a transmission jack I'd highly recommend borrowing or buying one for this job. Even a cheap Horrible Freight / Northern Tool one will be a huge help and allow you to do it by yourself. No doubt you could get it off without one, but to go back on it has to be aligned almost perfectly and the transmission jack allows you to adjust the alignment and still roll it forward to stab it in. Plus, there is so little room between Lefty and the gas tank and the transmission hump that there's not much room to work it without the up and down and axial adjustments of a trans. jack.

 

[Capt Sensible]

Jerry, if you don't have a transmission jack I'd highly recommend borrowing or buying one for this job. Even a cheap Horrible Freight / Northern Tool one will be a huge help and allow you to do it by yourself. No doubt you could get it off without one, but to go back on it has to be aligned almost perfectly and the transmission jack allows you to adjust the alignment and still roll it forward to stab it in. Plus, there is so little room between Lefty and the gas tank and the transmission hump that there's not much room to work it without the up and down and axial adjustments of a trans. jack.

this is pretty hilarious if you put your mind in the gutter!

 

[Mtbcoach]

Jerry, if you don't have a transmission jack I'd highly recommend borrowing or buying one for this job. Even a cheap Horrible Freight / Northern Tool one will be a huge help and allow you to do it by yourself. No doubt you could get it off without one, but to go back on it has to be aligned almost perfectly and the transmission jack allows you to adjust the alignment and still roll it forward to stab it in. Plus, there is so little room between Lefty and the gas tank and the transmission hump that there's not much room to work it without the up and down and axial adjustments of a trans. jack.

I'm debating that right now, thanks for the feedback. One of my club buddies made "adapter plate" so to speak for his floor jack that I was contemplating borrowing. But, I've got a Harbor Freight 20% off coupon sitting on my desk that could help justify buying one. It's a pain in the @ss just getting the Bud's off let alone dropping the Lefty. I've got to remember I'm not as young as I used to be and need to work smarter, not harder...

this is pretty hilarious if you put your mind in the gutter!

It could be construed to be some of the best marital advise I've been given...

 

[SWITAWI]

...so its about time I got intimate with my Inchworm...

And you probably typed that with a straight face... lol.

Be sure to take more pics for those of us that can't get greasy with you. I'm interested to see the inchworm up close.

 

[Mtbcoach]

Finally accrued enough time under the FJC to get the Inchworm out and free to clean up/inspect. Glad I ponied up for the cheap Harbor Freight tranny jack.

Fresh out of the mess, just a bit of overspray mixed with sand, makes for a nice and destructive compound...

Hit with some simple green and the power washer, just a bit cleaner...

The drain plug paste is pretty thick and tall, found one small sliver but mostly heavy paste...

Tomorrow, I'll break it down...

 

[Capt Sensible]

Nice.

 

[FJNewb]

Harbor frieght tranny jack is my best friend...definitely makes pulling the case much easier.

 

[Mtbcoach]

Got it open and broken down for the upgrade. Things looked good inside, nothing I could identify as being a problem but I'll be cleaning all the gears up for a close inspection tomorrow...

Since I broke it down, I had to clean things up and consider a color change. As much as I can appreciate the "Inchworm blue", if I had one of the blue FJC's, I'd keep it. One thing I can say is that the powder coat Inchworm is thick and stronger than any I've dealt with before. Sandblasting, the powder coat took it and laughed back so I had to resort to chemicals. Found some "aircraft stripper" and it worked well.

Just too many nooks and crannies, it took me half a day just to get it clean and ready for a new color. Here is the pile of parts that will occupy most of tomorrow playing with and trying to get everything back the way it came out...

 

[Capt Sensible]

Man, that looks like a project right there! Good luck!

 

[BirdManzFJ]

Jerry, that just crack's me up. Thinking back when we did my lefty at Buds. My buddy Duster was ragging me about putting something "BLUE" on my rig. Once we got the lefty in place, I took a sharpie and wrote " GAY BLUE" on it, snapped a quick pic and sent it to Florida. A couple days later, Bud, his son Nate and I were up in Tenn for a 4X race. Sitting at a red light Bud spots a Voodoo FJ and says" there's one of them Gay Blue Fj's. I about pee'd my pants.

I have done the output seal twice now, wondering if I need to do this as well.

Martin

 

[1911]

Pretty sure that my output seal is leaking now too; have to check it and the bearing soon.

 

[Mtbcoach]

Jerry, that just crack's me up. Thinking back when we did my lefty at Buds. My buddy Duster was ragging me about putting something "BLUE" on my rig. Once we got the lefty in place, I took a sharpie and wrote " GAY BLUE" on it, snapped a quick pic and sent it to Florida. A couple days later, Bud, his son Nate and I were up in Tenn for a 4X race. Sitting at a red light Bud spots a Voodoo FJ and says" there's one of them Gay Blue Fj's. I about pee'd my pants.

I have done the output seal twice now, wondering if I need to do this as well.

Martin

I don't know if my color choice is any less gay but at least I'm being constantly gay with my color choice.

I justified it due to the slop I discovered, fearing the bearing needed service/replacement. But, the new oversized Marlin stuff is very nice...

Pretty sure that my output seal is leaking now too; have to check it and the bearing soon.

Sorry to hear that Lee, lets hope its just the seal unless you need an excuse to do the upgrade also...