Front Hub & Knuckle Removal: For the last time - we're taking apart the front hubs & knuckles for a cleaning and rebuilding. After this is complete, the axle will be delivered to Way Cool Rod Shop for some final welding work on the perches. We have an official date with Hoaks 4WD in Mechanicsburg PA on April 8th to have the gears, lockers, bearings, & seals installed on both axles.

Ball Joint Removal: As you can see in the picture, we didn't remove any ball joints just yet. We came across something that was a bit unfamiliar to us. These ball joints don't just press out. After spending about 2 hours on the internet trying to get information on how to remove these things - I discovered we needed a tool called a "Ball Joint Spanner Wrench".

I spent another hour or so driving around town trying to find one - none of the auto parts stores have one.

I finally ordered one from a Napa Auto parts. They had to order it special for me.

ARB air compressor install

Rear Axle Paint Job: While I was working on extending the rear differential breather hoses and finishing up with the CB wiring, Steve began prepping and painting the rear axle with POR 15.

Painting the rear axle with POR15

Old U-bolt welded to side of diff housing

Fabricated Front Perches: The front axle came back from Way Cool Rod shop in Lancaster Pa. Mike did an awesome job!! After our front axle test fit - we found the u-bolt (left or outer side) would be mounted on the edge of the diff housing and not the tube. We asked Mike to weld this old u-bolt (seen in picture) to the edge of the diff housing as a safety precaution to prevent the u-bolt from coming off the edge. Not that we'd expect the u-bolt to come off the edge, but under heavy rock crawling situations - I'd rather be SAFE than sorry.

On this same side of the axle, there were 2 small areas where the leaf springs were not supported. We didn't need to get these 'voids' filled, however, Mike was able to weld in some angle steel. The entire area of the leaf springs will be supported now.

The other side of the axle - the picture below shows the area we had to cut away to accommodate the u-bolts (right side of perch in picture). Mike welded a 1/2" piece to the other side of the perch (left side of perch in picture).

'Voids' filled

Ball Joints : It's been a few days since we worked on the ball joints and steering knuckles. It took us a while to learn how to remove them. After purchasing a ball joint spanner wrench and a 3lb sledge hammer, finally the ball joints & knuckle came off the axle. Stress relief.....3lb sledge hammer.....and WHAM!!! many times.

We totally removed the ball joints from the knuckle. We will be getting replacement ball joints and saving the old & dirty ones for spares if needed (on the trail).