Johnny's Dart repairs

Dave999 · Post by **Dave999** » Fri Feb 28, 14 9:10 am

all the dana/spicer/borgwarner axles are the same

all shims and no threaded adjusters

dana 44 has been around since 1940s you just have a modern version. its going to be well supported and not just by the aftermarket

RATECH

will have all the bits you want for installing your centre

but then again your local jeep garage probably does as well

http://www.ratechmfg.com/dana.htm

dana instructions they are all the same

http://www2.dana.com/pdf/AXSM-0053.pdf

Dave

Johnny Dart · Post by **Johnny Dart** » Sat Mar 22, 14 8:30 pm

It looks like I'll be starting the rear axle next week now.
Everything just seams to get in the way !

I only had one kick panel when I got the Dart, so was about to import another one , when I came across these kick panels with speakers built in,
so I imported these instead.
I fitted them today, together with a pair of parcel shelf speakers.

autofetish · Post by **autofetish** » Sat Mar 22, 14 8:34 pm

good place for speakers

great work

Johnny Dart · Post by **Johnny Dart** » Wed Mar 26, 14 10:29 pm

I mounted up the electric fan this evening, it's a 16" 120w item.
Wired up through a fan switch,that I fitted to the bottom tank of the rad , in place of the drain bung.
I cut out the drain bung , and soldered in a brass thin nut , to take a generic 22mm fan switch.
This is wired through a relay, to operate fully auto.
Have to see how well it works

Lower rad crossmember has taken a bit of a poggering, and will need to be straightened out, while the rad is out

Johnny Dart · Post by **Johnny Dart** » Fri Mar 28, 14 9:22 pm

This evenings job was to straighten out the rather bent ( see pic 2 above ), radiator cross member.
It was quite a job , as it was very bent and stretched, but it came back into shape fairly well,although it split a bit !
Weld up the splits , a bit more hammering, clean up with the grinder, paint.

autofetish · Post by **autofetish** » Sat Mar 29, 14 8:01 am

Ratchet straps took me years to work out that trick .

Great work on the rad love the temp switch mod very clever

Johnny Dart · Post by **Johnny Dart** » Sun Mar 30, 14 4:40 pm

A bit more hammering, a bit of welding, a bit of grinding, a bit of drilling, and a bit of under seal painting.

Johnny Dart · Post by **Johnny Dart** » Mon Mar 31, 14 9:46 pm

Well .I didn't get around to doing and more workn on the axle shortening last week , so I'm on to it this week in my lunch times at work.
:

Rear discs have been re drilled to 4.5 PCD

Axle ends being cut off

3 3/4 one end and 3 1/4 the other

autofetish · Post by **autofetish** » Mon Mar 31, 14 10:35 pm

I slaged you off but if you pull off this axle I will be very very impressed and take it all back 😊

Johnny Dart · Post by **Johnny Dart** » Tue Apr 01, 14 7:10 pm

autofetish wrote:I slaged you off but if you pull off this axle I will be very very impressed and take it all back 😊

I've started it now, and will see it through, whatever it takes

I'll end up with a light weight aluminium axle, 3.73 heavy duty gears,a positive locker, and disc brakes.

Johnny Dart · Post by **Johnny Dart** » Tue Apr 01, 14 7:17 pm

Today's lunch time task. Clean up the axle ends, that I cut off, chamfer the ends,press in the locating tubes,press the ends in ready for welding.

Mossy68 · Post by **Mossy68** » Tue Apr 01, 14 8:21 pm

Impressive stuff JD.
Great thread. Keep the updates coming.

Johnny Dart · Post by **Johnny Dart** » Thu Apr 03, 14 7:01 pm

A bit more lunch hour work today.
Welded the axle ends, and now finished the axle, apart from offering it up with the wheels on , and centralising it with the wheel tubs, and leaf springs, tack the spring perches, with the right pinion angle ect.

I now need to start on the half shafts.

Welds placed to minimise distortion.

Welding round the ends.

Done

Steve · Post by **Steve** » Thu Apr 03, 14 7:36 pm

Very nice work mate...and looks like you have all the kit as well....fantastic!

Johnny Dart · Post by **Johnny Dart** » Thu Apr 03, 14 8:15 pm

Steve wrote:Very nice work mate...and looks like you have all the kit as well....fantastic!

Thanks Steve, yes I do have access to tools ect, and it does make a job easier.
Still quite a bit to do. The shortening of the axle case was quite easy, and I could do it all myself.
Shortening the axles themselves is another story.
I can't do that, but have a friendly guy with a machine shop that has a cunning plan to shorten the shafts.
I then need to fit the diff centre locker.
Watch this space