Here are all the parts for the sway bar link. I have two of these to do.
I started off installing the u-bolts on the spring I already installed. Then I decided to install the Panhard bar before the driver’s side spring was in the way.
After work I got back on putting the suspension back together. First step is to hang the sway bar. The replacement bushings I got are not an exact match. The new ones have these ridges on them that will not fit in the brackets so I trimmed them off with a sharp knife.
So now I have a size mismatch problem. I will have to get creative to push the rubber over the bar.
This is what I came up with. I lubed the bushing up with silicone and used the clamp to push it on. It worked like a charm.
I did the same thing on the other side and wiggled the bushings into place.
Hanging the sway bar is a three-hand job so I used a couple of C-clamps to make a sway bar holder. Once a couple of nuts were started the rest went easier.
All the nuts are in but not tight. I will do that later once the sway bar links are attached.
The theme of the day seems to be putting things into holes too small for them. Now I have to figure out how to put the bushing into the spring eye. Plan A was to use the chisel technique I used to get the old bushings out. That almost worked but when I flexed the eye the eye was oval rather than round and I could not get the bushing to start in there. So I started working on a plan B.
This is plan B. After greasing the bushing and the eye I found an old bearing race the same diameter as the bushing and used my vice to press the bushing in. It worked very well. Interestingly there is a right side and a wrong side to start the bushing in from. I could only get the bushing to start from one side of the spring.
Just like a new one!
So this is one axle’s worth of new hardware. The only snag here is that the new u-bolts are a LOT longer than the old ones.
I started hanging the spring from the rear frame mount. Shiny!
Then the new spring shackle at the front. I lubed the bushings up with silicone grease and bolted them in.
With the spring secure I used the jack to set the axle back down on the spring. Now I need to install the spring plate and clamps. But as I noted before the u-bolts are way too long.
So I did this. Frankly I am not sure the die grinder with a cutoff wheel was any faster than using a hacksaw but it certainly was more dramatic. Notice I threaded on nuts before cutting off the bolts. After the cuts were complete I dressed the cut ends with a file then backed the nuts off to clean out the threads.
Freshly cut u-bolts ready to go. I really wanted to keep going here but it was getting really late and I was really hungry. So this will have to continue tomorrow.
Much of today was spent under the Jeepster getting really dirty.
It was cold this morning but I really want to get this suspension cleaned up and painted this weekend. So I started working on the other spring.
I have been really slacking off on the Jeepster since winter kicked in.
I am going to take the tire that is leaking in to get it fixed. Not a bad job but I managed to hurt myself.
So last year I want to a conference and won this Parrot minidrone. The quadcopter is about 10cm across and you can fly it on its own or snap it onto the boat and run it around a pond. It is a fun toy but I have not played with it for a while. Today the winds were calm (sort of) so I charged the drone up, hopped in the Jeepster, and went to a local softball field to play.
The new flasher came today so I put it in. Works fine. But what is up with the old flasher?
It took a little careful prying but I snapped cover off the old flasher.
There is some ugly soldering on this but I don’t see anything super suspicious. I will take this to work tomorrow and poke at it under magnification. The good news is the Jeep is flashing again.
I examined the flasher under a microscope and re-soldered the messier solder joints. It still does not work so I threw the flasher away. Better yet is I drove the car several times over the last week and nothing new broke.