U-joints...can I just say they suck all around? Well they were a pain coming out, and just as much a pain going back in! I basically destroyed them coming out. I used a hammer, an old socket and myself to beat them out. The front u-joints came out no problem...I think they have been replaced sometime in the no so distant past. But the rear drive shaft...I think they were the original ones. They took me some time to get out and I had needle bearings all over the place! Once they were out though, I was able to paint up the drive shafts and flanges and have them looking new. The new u-joints were a bit easier, but still not the easiest thing in the world. Basically I used the same method for taking them out, but much more carefully and with a rubber mallet instead of a sledge hammer. They eventually went back in and the drive shafts were complete.
The parking brake was a mess. The rear output seal of the T-case had failed and transmission fluid had leaked inside and basically became a solid mass. It took some work...lots of soaking in thinner, but everything eventually loosened and I was able to clean, paint and put the parking brake back together.
Next up was to install the parking brake on the T-case and the drive shafts. The front drive shaft went in without any problem. The parking brake installed with no problem. The rear drive shaft...problem! Apparently with all the modifications I made to the rear suspension, the distance from the parking brake to the rear third member flange has shrunk and the drive shaft is about 1/4" too long now. I figured it would have been the opposite...shorter than the distance. At least in that case I would have some slack with the slide yoke. My guess...without the weight of the body and interior, the rear suspension is not at the proper location...basically it needs the weight to push the shackles out and increase the distance from the T-case to the rear axle. I guess I'll test that theory in a few months.
Otherwise its been all about paint removal. I'm very close to having it done! The top side has a few areas that need to be completed, but for the most part its finished. I am trying to figure out what to do about under the dash. I figure I'll clean, sand and just leave the old paint on. Nobody will see it and rust doesn't seem to be a huge issue under there. So far the only metal I'll need to replace...the outer rocker panels on both sides, the rear sill, and patch panels on the lower rear quarter panels. I'll also have to fill a couple of spots in the bed but that shouldn't be too bad. I'll also have to work on the driver side flow pan...I can see the ground through a few holes. My goal is to get the paint removal done in the next week or so, then flip the body and sand the under side. I know its mostly surface rust under there, so that will clean up nicely.
