Jack Stilts' Build - 2002 ABT (Armored Baby Transport)

[caseycamby]

I read where you were drunk then I looked down at the picture and thought, "ohhhh noooo, this can't be good" hahaha

 

[Prime]

Dude. Stoked. But saddened.

 

[Prime]

What exactly happened?

 

[Jack Stilts]

I feel exactly the same.

The seal kit that I got to replace the leaky ones had been put in, but I must not have pushed them up in there far enough. Thinking about that is baffling since they were hammered in...

It was kind of funny - I went out this morning to check out the crime scene and see how bad it was, and the seals, all four parts, are just hanging there above the pitman arm. Just taunting me. "Hey. What's up. You wanna do it right this time?"

 

[Prime]

That's bizare. There's no kind of retaining ring to hold the seal in? It just a press fit?

 

[Jack Stilts]

Two rubber seals, one metal washer, and a snap ring. I'll see what happens after another go. I'll be sure to cram them in there.

 

[Prime]

Yeah. I'm wondering if the snap ring didn't seat properly.

 

[Jack Stilts]

I almost wonder if there's an indentation up in the gear where the snap ring is supposed to "lock in" to, you know? Maybe I had it off by a few millimeters and didn't set it in right. At any rate, she's going under the knife (again) right now.

 

[Prime]

There has to be a groove for the snap ring.

 

[Jack Stilts]

So, funny thing. There's not. How does that work.

 

[NismoFire]

Are you pushing it far enough? There HAS to be something for that snap ring to sit in..

 

[Prime]

Are you pushing it far enough? There HAS to be something for that snap ring to sit in..

 

[Jack Stilts]

Yes, I understand the concept, ya dweebs.

I got everything disassembled and put the seals in again only to be greeted with a vengeful thunderstorm for the rest of the day, so it's going to be yet another day incomplete.

I'm sort of peeved that I was able to get the idler arm removed without taking anything else apart, but getting it back in is going to require dismantling the entire system. The other part to this? I'm not going to know if my second attempt with the seals is going to hold up until there's enough pressure in the system to pop them out again. Ipso facto, I'll only know once it's completely back together.

 

[TJTJ]

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Haha! No, it was a South Park reference (sorry, Jay).

Well, sports fans. I finally got the Total Chaos steering kit installed.

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This was my weapon of choice, mostly for the pitman arm nut - a five-foot iron prybar.

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Look at how clean that pitman arm is! This thing hasn't been dry in two years. I put in a new seal kit to stop the leak.

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She's all put back together now.

Some notes / thoughts:
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I was completely astounded at the fact that I was fully able to do this on my own. I started it around 6pm and was so drunk on success that not only was I nearly done, but it was 1am and I hadn't noticed.

However, my elation was short-lived. Once it was put pack together, wheels and all, I put power steering fluid into the reservoir, turned the truck on, and turned the wheel.

Ouch. The seals didn't hold. So I'll be taking the idler arm off again to investigate.

I can't express the sheer disappointment I felt after such a victorious project. This was the biggest undertaking I have ever accomplished on a vehicle by myself, and to see that was just crushing. Ah, well. She'll be good to go in no time.

Unless my ADD etc is kicking in (normal actually..) I think this shows the two grooves for the rings, etc.

Does that help?

 

[Jack Stilts]

Haha, no, you're right. The grooves would have to be on the inner side of the actual gear housing itself. The snap ring compresses and then expands outwards to hold the rest of the seals up in the shaft.

 

[Prime]

So, why do you have to put everything back together? Can't you just get the seals in, leave the pitman arm off and start it up? As long as you mark the steering shaft and pitman arm. You can turn the wheel and you'll still pressurize the system.

 

[Jack Stilts]

Correct, but not enough pressure to blow the seals out like I did last time. There is only enough pressure when the arm is trying to turn the wheels. Trust me, I've already tried it without re-assembling, and, well...see puddle above.

 

[Prime]

Gotcha. So you can pull the pitman arm without doing anything else, but you have to pull the entire system to put it back on?

 

[TheFauxFox]

So, why do you have to put everything back together? Can't you just get the seals in, leave the pitman arm off and start it up? As long as you mark the steering shaft and pitman arm. You can turn the wheel and you'll still pressurize the system.

I thought this procedure throws off your clock-spring?

 

[Prime]

Don't see how it could. The steering wheel and steering box are mechanically joined. Now you could over rotate the wheel and damage the clock spring because there's nothing to stop the steering with nothing connected.

 

[TheFauxFox]

Don't see how it could. The steering wheel and steering box are mechanically joined. Now you could over rotate the wheel and damage the clock spring because there's nothing to stop the steering with nothing connected.

I bring it up because when I was swapping out my steering box in my TJ for a Durango V8 box it was recommended that you do not touch the steering wheel. After doing it, I noticed my airbag light was on and I lost cruise, both of which are connected through the clock spring. I relieved myself of the Jeep so I have no idea if that was actually the culprit.

 

[Jack Stilts]

Yeah, I didn't see anything about that in the instructions.

On that note, second attempt was also unsuccessful.

 

[Prime]

Dafuq!

 

[Jack Stilts]

Dafuq indeed. Going to have to find some local assistance.

Only have two weekends left to wrap this up and install an AAL before heading to the upper peninsula.

 

[drbandkgb]

Aal is pretty easy

 

[Prime]

The AAL is stupid easy. I want to know wtf is up w/ your steering box.

 

[Jack Stilts]

Right, I'm not too worried about the AAL.

Getting some assistance on the box this weekend from an ex-Nissan tech.

 

[NismoFire]

Where did you get your kit from, anyway? I tried finding one but not at any of the local haunts..

 

[Jack Stilts]

Got mine from Danny last year, but he said there were issues getting it from his supplier, so he quit offering it. I know you can get it from AC 4x4, though. And I swear you can get it from one of the sponsors, but I don't remember which.

 

[NismoFire]

Got mine from Danny last year, but he said there were issues getting it from his supplier, so he quit offering it. I know you can get it from AC 4x4, though. And I swear you can get it from one of the sponsors, but I don't remember which.

I checked our sponsors and couldn't find one. Dang it, #DanAmigo!

Any luck with the Nissan mechanic?

 

[Jack Stilts]

I checked our sponsors and couldn't find one. Dang it, #DanAmigo!

Any luck with the Nissan mechanic?

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Weird. I swore it was RR, but you're right - no dice.

Nissan guy said the same thing y'all are saying, and what I already know. He's coming out tomorrow since I can't really drive in anything but a straight line.

 

[NismoFire]

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Weird. I swore it was RR, but you're right - no dice.

Nissan guy said the same thing y'all are saying, and what I already know. He's coming out tomorrow since I can't really drive in anything but a straight line.

Hey, the shortest distance between two points is, in fact, a straight line.

 

[Jack Stilts]

Not according to The Glitch Mob...

[video=youtube_share;nrGhZmpoIDc]http://youtu.be/nrGhZmpoIDc[/video]

 

[Jack Stilts]

‎Need some help, XN.

Finally finishing up this steering gear seal kit, but I've got one last question before I do:

The diagram that was provided to me says that the snap ring (retainer) goes in last before the washer & nut on the end of the pitman shaft.

My question is this - the snap ring does indeed have a groove to fit into, but it's so far up the shaft that there is only room for one rubber washer to fit before it's put into the grooves.

If I put them in this order - rubber washer, snap ring, second rubber washer, metal washer, lock washer, nut - is it going to be worth it to try this method, which goes against what the diagram says? There's no room to cram all these things in before the snap ring. I want to follow the instructions provided, but also don't want a third unsuccessful attempt. ‎

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/sorryforstupidquestions

 

[Prime]

I'm gonna call BS on that diagram. If you put it together like that I'm not surprised you had two failures. There's no way you can put a lock washer and nut holding pressure on a rubber seal and a snap ring. Especially if the snap ring isn't in its groove. It just isn't going to hold. The lock washer needs to be between the flat washer and the nut to apply the appropriate pressure to actually... Well.... Lock the nut. I definitely think you're on to the right track with your proposed assembly method.

I wouldn't be surprised to see another flat washer over the first rubber seal and placed under the snap ring so that the pressure is evenly distributed to the outside edge where the snap ring has its strength.

 

[Prime]

Yeah. Just took another look at the diagram. That's exactly how it needs to be.

Bearing, seal, washer, snap ring, seal, washer, lock washer, nut.

 

[Jack Stilts]

Stupid diagram.

Thanks, Jay. The way I see it / the way you mentioned made sense, but I didn't want to chance going against the diagram.

Solution = kill the diagram! Problem solved.

I'll be giving it a go tomorrow. Fingers crossed that logic will win.

 

[Jack Stilts]

Good news / bad news!

Brand new steering gear has been installed. Total Chaos steering system complete.

It was magnificent to be on this side of the steering wheel for the first time in...a month or two.

However, my excitement was short-lived when I hopped on the freeway and my wheel fell off.

Turns out I have a few stripped studs that need to get replaced before leaving for WENT tomorrow. Also need to figure out why there's so much air in my brake system. Also need to go find my rogue wheel & tire...

 

[caseycamby]

Whoa! It fell completely off?? Did it do any damage to the X?

 

[Roadwarrior]

Yeah.. I am with Casey..

I am impress that you were able to get it to the side of the road without it crashing..