Assembly Begins!

We started the assembly process this weekend. We still have the differentials to replace but our differential spreader tool did not arrive this week so we have to delay that one last big project. This weekend we did the following (that I can remember):

• Finally were able to get the rear axles out after getting a heavy duty puller designed to allow you to use a sledge hammer! It worked, at least for one side, the other side we went a different route and then used the 20 ton press to get the hub of the axle shaft, but it is done!
• Installed the upper and lower ball joints
• Replaced the motor mounts
• Installed the radiator, radiator shroud, new radiator hoses and the front grill
• Installed new rubber bumper guards on the grill for the hood
• Installed the firewall to grill strengthening rods
• Installed the battery box and supporting brackets
• Installed the brake, clutch and gas pedals assemblies
• Installed a new gas pedal to carburetor cable
• Installed the master cylinder
• Installed the ignition module
• Installed the new oil line for the new oil gauge
• Installed the sending unit and line for the temperature gauge
• Installed the main fuse panel and the main wiring harness under the dash
• Did troubleshooting of the OEM gas gauge and temperature gauge, ordering new gauges, wiring OK
• Installed the new fuel tank to filler neck hoses
• Rebuilt front brake calipers
• Wired in new LED tail lights, installed one of them, need to paint the license plate bracket before the driver side can be installed
• Cleaned up the engine compartment wiring, re-sheathed all the wiring with fresh sheathing
• Installed new U-joints in the freshly painted front axles
• Painted the roll bar
• Installed the OEM exhaust manifolds

Roll bar before painting

Headlight assemblies, all sand blasted and ready for paint.

All the cleaned, sand blasted and painted parts, before we started assembly.

Our "huge" puller to get the rear hubs off the axles. It was not easy! If you ever need one this big, we have one now!

One of the rear axles, we won't be re-using them, we purchased new G2 rear axles.

Rear axle housing after removal of all parts, oil seals and bearings. Ready to be cleaned and everything re-installed (after differential replacement).

The pile of removed parts that we won't be re-using is about complete, just the differentials and some small parts here and there and we should be done.

Freshly painted steering knuckles, with new upper and lower ball joints.

New u-joints in the front axles.

Rebuilding the front brake calibers.

OEM exhaust manifolds re-installed after sand blasting, high temp primer and paint. We removed the headers for the rock crawling trip to Moab.

All freshened battery tray and support brackets. Just need the front fenders to finish the one lower bracket bolt.

Starting to look like a Jeep again.

Brake, clutch and gas pedals installed. Fuse panel and main wiring harness roughed in to allow us to troubleshoot the fuel and temp gauges. They were not working when we bought the Jeep.

Our OEM to new technology LED tail light wiring diagram.

Another high quality Farver wiring job, everything stripped, soldered and shrink wrapped. We never have a wiring problem when we take the time to do it this way.

And finally, one of the tail lights installed and wired with extra protection from trail hazards. You never know what we might get in to. Especially in the woods on our property and in the Eastern US.