Entry 26: Axle Swap

Eliminated all the vibration from the driveline by replacing the axle bearings and the u-jonts, however when re-installing the driveshaft on the lift the pinion flange had endplay in it (could move pinion flange around by hand between 1/8" and 1/16"). Not a significant amount but it was definitely noticeable. Took the 86 out for a drive and immediately felt/heard clunking from the axle whenever I let off the accelerator and over 45 mph. With all the vibration before I didn't notice the thunking. Something is clearly not right, after investigating learned I needed either a rebuild or a fresh axle. Could not re-use the gears because the ring wear pattern is now uneven from the floating pinon and would generate a whine, picked up a used 8.8 axle for $225. 

 

Spent 8 hours over two days this weekend pulling out the old axle, stripping it and installing the replacement one. Found it easier to unbolt the lower control arms and upper control arms at the axle, which made the swap fairly straightforward. Swapped the following over: parking brake cables, differential cover with the fill plug brazed in, full drum brake assembly with new master wheel cylinders, and brake rotors. While I had the axle out I replaced the worn shocks with a new set of Monroe Sensatrac's.

 

 

 

Swapping Axles

Old 8.8

 

Entry 25: New U Joints

Pulled off the driveshaft in search of the continuing vibration, after swapping out the axle bearings it is significantly reduced but still present. Stopped at NAPA and picked up 2 heavy duty Precision 280 U-Joints to install. Pinion flange requires a 12 point 12 mm wrench to remove the four driveshaft bolts. Used the "big socket, little socket" trick to remove the caps and a bench vise to press the new ones in. Re-installed the driveshaft (don't forget the loctite on the flange bolts) and fired it up. Significant improvement in performance and reduction in vibration.

Entry 24: Axle Bearings

I had forgotten how nothing stinks like gear oil!!!

Took the 86 out for its first drive last week since its "rebirth" and heard a disturbing rumbling noise from the rear. The faster I went the worse it got. When took it up to 50 and put it in nuetral it made no difference, the sound remained. My thoughts were, "all that work and its still not right."

Pulled the tires off and was able to move the axle shafts around, way too much endplay. Very noticeable. Assumed it was the bearings so I put it up on the jack stands, opened the pumpkin, dropped the crosspiece and C Clips and pulled the axles out.

As suspected the outer axle bearings were shot and grooved/scored the axle shafts to the point that I could feel the ridge with my nail. Had read somewhere online axle savers were available to use so purchased a pair of #RP5707's at Advance. Its a cool part, combines the axle seal and the bearing into one unit you just press in and it pushes out where the bearings contact the axle shaft.

 

Rented an axle bearing puller from Advance and used it to yank out the bearings, took all of 5 minutes with the right tools. Can't imagine trying to break those out without it, what a nightmare it must be.

Used a bearings race (disc shaped tool of some sort at the shop) and brass hammer to press the bearings in and loaded everything back up. The passenger side was a bit snug at the outer axle seal causing the axle shaft to need a bit of help to go in but it all went back together. Likely over pressed the bearing a touch but it'll be fine for a weekend driver.
 .
Took it out last night for a long drive to get all the fluids moving around, the car probably hasn't been driven in at least a year so it took a few minutes to get up to temp but everything went well.

Entry 22: Updated Pictures

With all significant repairs are completed I pulled the 86 out of my Dad's shop and washed it, what a difference soap and water makes.....

All the new weatherstripping held up well and the interior is quite comfortable. Need to get a few floormats.

Noticed the paint is a metallic grey in the sunlight, have to wet sand with 1500 grit and buff/polish to really bring out the finish. Couldn't believe how well it ran and looked. When I was washing it I could feel on the sponge the surface is slightly rough and needs a good cut and polish.

Video clip (Quicktime):

(The red item on the drivers seat is plastic I use to protect the interior when I am working on it)

Pictures:

Entry 21: Exhaust Manifolds

I have a set of set of 1½" MAC Performance Unequal length shortie headers left over from another project, all they needed was to be cleaned up and painted. Used a wire wheel to strip off all the old material and coated with two layers of 1200 degree satin paint. The heat will cure them yielding a nice Satin Black color. These always outflow the stockers so it should yield a nice sounding exhaust.

Before:

 

After:

 

Entry 19: Rocker Panel Repair

After searching around for the correct color to match the current finish, finally had a chance to paint the Rocker Panel. When the passenger side floor pan and lower toeboard rotted through, it also obliterated the rocker panel, so when I replaced the floor pans last year I also repaired the rocker.

Back in September I had to create the metal patch for the area. Could not find any repro patches so I had to fabricate a piece up with the MIG and scraps from the pans. Then used Rage Gold filler, block sanded, repeated, skimmed with lightweight filler and final sanded. Gray filler primer followed by Metallic Gunmetal Grey paint. The entire car needs to be sanded with 1500 grit sandpaper and polished out, which will include the final portion of this repair. Plan to re-spray the entire car in the near future, but would ike to drive it for while before taking it apart again!.

July 2010

 

September 2010

 

<-Blocked

Primed ->

December 2010