1984 Jeep CJ-7 Progress 2011 10 25

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In the last update I installed a new steering gear box, in this one I take it back out.

I purchased this Jeep after looking for a Jeep that basically had not been modified and was in really sound condition. I really could not test drive it as it was unsafe for the road with the steering the way it was.

I diagnosed it to be a steering box problem, by running the jeep and turning the intermediate steering column with my hand (power steering), and watching the pitman arm. I could turn the intermediate steering column ¼ turn before the pitman arm would even begin to move.

So….. with 85,000 miles on the Jeep and 31 inch tires, wanting a reliable daily driver, I replaced everything from/including the intermediate steering column to the steering knuckles (heavy duty intermediate steering column, AGR steering box, used the old pitman arm (powder coated it) all moog tie rod ends.

I took it for a test drive and it was much better, but the steering wheel would not return after a corner. I called AGR and explained what I had done and that I thought the steering box was tight. They wanted me to put a 100 miles on the box and call them back.

I took it to the alignment shop and everything was off toe, caster, camber.

It was diagnosed as Bad front ball joints, sagged front springs.

So…..rather than install new stock springs, and knowing I wanted a small lift to try and retain the stock look I installed a complete Old Man EMU 2.5 lift kit (This is actually a YJ to CJ conversion as Old Man EMU does not offer springs for the CJ (difference being the front spring width)). Installed four Moog Problem solver ball joints, and install two new universal joints while the axle was apart. I would have replaced the seals but could not find the correct ones and will go back and do that when I have them.

Returned to the alignment shop. They installed Caster wedges and all the measurements (caster, camber, and toe) were set on the money.

The steering wheel still does not return after a corner. As yet I still do not have the requested 100 miles on the gear box.

If I crank the wheel full left or right it just goes in circles with no attempt to return to center.

When I was putting it to gether I started at the Intermediate steering column and worked my way down.

I tried tuning the steering wheel with just the intermediate shaft and the box no pitman arm or tie rod end and it was very stiff.

I will jack the front end up today and try turning the tire and wheel with everything hooked up, than separate the tie rod from the pitman arm and try again.

Pulled the Jeep into the garage and jacked up the front.

I could not move the tires left or right even with both hands.

Rather than pop the tie rod end and tear the boot with the pickle fork I pulled the pitman arm.

I can move the tires left and right fully with one hand with very little effort.

I knew it when I turned the steering wheel the first time after I installed the box and felt how tight it was the box was not right.

I was in a hurry to get to drive it. I should have stopped right then and there and sent it back. They had done a welding repair to it and the bolts did not align correctly either.

Now I’m going to do it right and take my time. I’m also going to fix the radiator spacing problem and install a fan shroud. http://www.jeepforum.com/forum/f8/radiator-fitment-gap-between-radiator-front-grill-1275286/

There are other tasks that need to be done while I wait for the new box (longer brake hoses, extend the sway bar links, replace all the sway bar and link bushings, the new carb is on the way so I can play with that also).

I’m also going to look at the drive line angle coming out of the transfer case and fix that if needed.   http://www.jeepforum.com/forum/f8/drive-shaft-angle-drive-shaft-length-2-5-inch-lift-1276807/

I was in such a hurry I did not take good pictures of the spring install. Below is the spring install.
Ok that is the background for this update.

	One picture just to let you see the new stance. I did not take any before the start of the tear down
	Ok, the springs are in , the alignment is perfect. the steering wheel does not return, It is the box, time to take it apart again. This is a continuation of the the process on the SS 70 El Camino
	Now it is time to get the bad box out
	Ok it is out, but wait what happened to the front of the Jeep, it is missing parts! Well the story is now I’m going to do it right and take my time. I’m also going to fix the radiator spacing problem and install a fan shroud. I’m also going to fix the rust on the windshield, front grill and paint the doors to match. So…………below are the pictures of the rust to be repaired
The doors that do not match and need to be painted
	As you can see I have door panels which ar the correct color for the inside. After the doors are painted I will put those in.
Top on, top off.
	Boy I wish I had left the front together and taken the top off first, I would have taken it for a ride even is the steering was messed up
	Parts are starting to pile up
Time for the windshield to come off, I caught the rust just in time.
Boy do I have a pile of parts now!