This weekend some buddies of mine are coming up to go camping and wheeling, so I have been busting my butt to get Caitlyn wheelable. I still have quite a bit to do before Friday and it will in no means be finished, but I should have it buttoned up enough to go play and see what else needs to be done. I was able to button up the wiring and bolt back on the front clip.



The brakes have been sorted and bled, so it should stop. LOL! I have been mostly working on the exhaust. The PO had it coming from the crossover pipe, to an O2 bung, then a long pipe, another O2 bung, the cat, muffler, and tail pipe. I figured I could just make two cuts, flip the cat around, and set it up correctly.



I measured it by eyeballing and figured I had just enough space for the cat. Well, I may have been a bit wrong. It is TIGHT! I ended up putting heat shielding around the wires and on the body trying to protect everything. I also exhaust wrapped the cat and piping under the floor. It ended up being so tight that the cat is touching the floor and the pipe is touching the crossmember. Like I said, it is stupid tight. I’m going to try it and hopefully not have to redo this exhaust.



I still need to build the muffler/tailpipe section, install the front driveshaft, clearance a link mount, build (jerry-rig) a coolant overflow bottle, secure the main chassis wiring harness under the truck, fill up the front diff, install the winch, and change the oil. I have two evenings to get it done…

 

Nice. Post some pics when you get back, like to see it in action.

 

At this point I still hope I can take her! I have time to get everything done as long as I don't run into problems on the way.

 

Believe it or not, I got Caitlyn "done" Thursday for wheeling. I took her for a test drive before packing and made it five blocks before the rear end locked up at 40 mph. I ended up in the median about 5' from a lamp post just before rush hour traffic. I honestly thought that it was going to roll when she went into the median sideways. It was probably the scariest driving experience in my life, and I've had some good ones!

Long of the short of it is I got her back in the garage and haven't even pulled the cover. I'm pretty upset about the whole deal, but it is what it is. Now I just need to find the $$ to get back working on her.

 

Well, shoot. Glad nothing serious happened. Do you know what locked up?

 

It's all speculation at this point, but I think the welded carrier let go.

 

I was able to get out of town, get my head right, and put a plan together (thanks to awesome friends and an understanding wife). The plan is to have the truck ready for Rubithon 2018!



This pic was taken while I was warming Caitlyn up for her first test drive. I was upset enough that I just got her back home and parked her. Last Saturday I figured it was time to pull the inspection cover and see just how bad the damage was. This is what I saw:



Yep, not a drop of lube. I ran on the assumption that the PO would have filled it, but I never checked myself. That is my own stupidity. However, there are no metal shavings and no heat marks on the gears. All the teeth on the r&p loop perfect. I think I just seized the pinion bearing! Talk about the best possible outcome of a bad situation... I am blessed! I am going to order a Detroit and a master install kit to rebuild the rear-end. Speaking of which, does anyone know how to set up gears that would be willing to come over and help me? I have helped with setting up Toyota 3rds before, but that was a long time ago.

 

WOW!!!!!!!!! Talk about lucky!

 

I've never worked with setting up gears, but I'm good at handing tools to people and would love to learn how. So if you need a hand just LMK

 

Thanks! Once I get everything rounded up I will let you know.

 

Wow, that had to be scary! Glad everything is ok!

Love the looks of this rig. Bet it'll do great on the trails too

 

It was scary! LOL!

 

Carl at JustDifferentials.com hooked me up with everything I need to get the rear end back together. I can't speak highly enough of Carl and his business. JustDifferentials.com and Nitro Gear are the ˟˟˟˟! As soon as I get the parts, I will be scheduling a work party!

 

Small update: I bought some seats. Rusty's Off Road was having a sale on MasterCraft Nomads, so I picked up a pair.




I was also able to pull the rear end apart with a buddy. Tons are big! As suspected, I just toasted a pinon bearing. I have never seen on this far gone before. It is amazing that there wasn't any other damage.




A week from Friday another buddy is coming over to help me set up the gears and the new Detroit locker. I also ordered new rear springs since I bent them pretty badly when the rear end locked up. After that I should be ready for a test run... This time with 90w in the rear end. LOL

 

Are you replacing gears too?

 

Those seats look comfy!!

 

Nope. I will replace all of the bearings and swap the welded carrier for a Detroit.

They are! Nice and wide with not too much bolster. I think they are going to work great. It was money that I probably shouldn't have spent, but they were on sale. LOL!

 

Can't beat a bargain!

 

I have had a few people bring up concern about the pinion gear being "overheated". Here is a couple pics (one with flash, one without) showing the pinion. As you can see there are no heat marks anywhere AND the other pinon bearing rolls smoothly with no signs of overheating. The only "damage" I can see is the slight galling on the bearing surface that can be buffed out with emery cloth.

 

You'll be fine. What's the worst that can happen?