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JeepFever
Member Sponsor Member Joined: 07 Aug. 2012 Location: VA Status: Offline Points: 2747 |
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After seeing your last post I was thinking that I need to go back and look at Seth's video of Southington. (On the rock pile -> is Barry holding on tight to steering wheel with both hands, wearing sticky gloves, -or- casually steering with one hand?) Sounds like it worked out for you.
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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The next part of the project was the steering column. I waned to use the original column and horn button. My column had a commutator attached to the inner shaft and a brush that the horn wire attached to on the outside of the outer tube that I could continue to use. From what I understand, some columns have the horn wire extending all the way out thru the Ross box. I don't know if you could make that type work once you cut the worm gear off.
Our first step was to cut off the worm gear leaving as much of the shaft as possible. I was able to do this entire modification without removing the steering wheel. It may have been easier with the steering wheel off but I didn't have a puller handy. There is a spring under the steering wheel that pushes downward on the outer shaft. I order to keep the brush in the correct position against the commutator I knew I would have to add a stop collar to the inner shaft to hold against the spring pressure. Next I cut the outer tube to length leaving enough space for the bushing below the commutator. The inner shaft is slightly larger that 7/8" in diameter and gets even larger near the worm gear. I held a flap wheel on an angle grinder against the shaft while tuning the steering wheel to reduce the diameter to 7/8". Later on I had to have Ron hold the outer tube back against the spring tension to be able to grind the inner shaft far enough up to go through the bushing. |
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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I made a drawing for the bushing.
I decided to make it out of a chunk of brass that I had set aside to make a hammer out of. Ron turned it on his lathe first drilling the ID. Then he turned the OD and flange then cut it off. Here are all the pieces ready to assemble. I used a 7/8" needle roller type thrust bearing between the bushing and the stop collar to hold the pressure from the spring and set the stop collar at the correct spot for the brush to run on the commutator. Finally the u joint goes on the end. (I ended up having to use a double U joint there.) Once I knew the final position of each steering part I installed 2 set screws with 1 drilled deep. Also in the photo notice the split sleeve around the column. The OD of the column is 1 1/2" and the clamp at the dash was sloppy. I bought a piece of 1 1/2" ID exhaust repair pipe and cut a split in it to tighten up the fit. Then I cut it in 1/2 so I had another piece for the floor mount. Column mounted to dash. I made a floor mount with a piece of angle left over from something and an exhaust clamp. For my intermediate shaft I used a 3/4"DD X 1"DD telescoping shaft that ran through the engine mount. I thought I was in good shape until I discovered that the angle between the intermediate shaft and steering column was a little too sharp for a single U joint. The solution was a double U joint but time was getting short and the part I needed was special order and very expensive through Borgeson. Luckily I stumbled on to Sweet Manufacturing in Michigan. https://sweetmanufacturing.com/home.php I talked to Mark there who built a 7/8" Round X 1"DD double U joint for me and shipped it the same day. Plus, they were way less expensive! Thank you Sweet Mfg.!! The double U joint was supported on steering column side, but I needed to support the other side also to keep it from flopping around and binding. I could have used a pillow block or a heim joint. Instead I started scrounging around in the barn where I found some spare garage door parts. It turns out that the rod above garage doors that the springs wind around is 1" and runs thru bearings mounted in a plate! There happened to be a couple in a box! With a little trimming and fabricating here is my garage door carrier bearing. Here is my parts list from the Saginaw power steering box back to the steering column: U joint - 13/16 36 spline X 3/4"DD Telescoping shaft - 3/4"DD X 1"DD 36" long (Cut to length) Carrier bearing mounted in plate - for 1" shaft (Garage door) Double U joint - 1"DD X 7/8" Round (Sweet Mfg.) Stop Collar - 7/8" ID (Amazon) Thrust bearing - 7/8" ID (Amazon) Bushing -homemade |
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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A couple of last thoughts on this part of the project. The reason I went with the telescoping intermediate shaft instead of a solid one was just to make it easier to assemble or disassemble. Also, as I mentioned earlier, I drilled and tapped for 2 set screws at every connection (belt and suspenders thinking). When I was drilling the set screw hole into the splined input shaft on the power steering box the bit suddenly went through. That shaft is hollow! I went ahead with the project hoping the set screw would plug the hole but when the system was pressurized it leaked there. I ended up taking it back apart and welding the hole shut.
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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jhg
Member Joined: 07 Nov. 2016 Location: colorado Status: Offline Points: 917 |
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Interesting but more important... can I borrow your brother??
Everyone with a machinist in the family, whether its you or a bro is pretty fortunate cause whatever I am able to do stops exactly where turning or milling parts begins.
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1948 cj2a. Rebuilt L-head, steering, T90, WO 636, steering, brake lines. So far.
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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Now it was time to install the new knuckles. That was pretty straight forward except that I only had to shim the top bearing cap because the knuckles are off a Dana 27. I added the full stack of shims first and kept removing shims until I had about 15lbs pull on a fish scale.
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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I forgot to mention that before I installed the knuckles I drilled the holes out to 3/4" to accept the inserts for the tie rod flip.
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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The splined hole in my pitman arm had 4 spots without a groove to index it with the steering box output shaft. Because I mounted the box at an angle to the frame I figured I would have to adjust the position. Using a new sharp 3 corner file I filed a groove into to those 4 spots which would allow me to place the pitman arm wherever I needed. As it turned out, the arm landed right back at an original spot so I would not have had to file in the extra grooves. I am guessing that if I had mounted the box parallel to the frame I would have needed the extra grooves to reindex.
I had to shorten the pitman arm to provide clearance between the new tie rod and drag link. I drilled a new 3/4" hole in the flat part of the arm as far back as I dared to receive a tapered insert. This made the center to center length 5 5/8". We then built up the sides with TIG to make sure it was good and strong and cut off the extra length. |
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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Now I could make the tie rod and drag link and tack the ends on to test fit every thing. I especially wanted to check frame clearance to make sure the tie rod flip would work with stock springs.
Once I was happy with all the fits and clearances I welded everything home. I had a hard time finding the tapered inserts. There were lots of them available that required a 7/8" hole. To avoid weakening the knuckle arms or pitman arm I searched for inserts that only required a 3/4" hole. I finally found TMR Customs in Ontario, Canada who had them. https://www.tmrcustoms.com/ Here they are tacked into the passenger side knuckle arm. Edited by Barry S - 26 May 2023 at 1:13pm |
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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The parts I used for the tie rod and drag link were:
Tapered tie rod end inserts part# 1573 Quan. 4 TMR Customs https://www.tmrcustoms.com/ M38 Tie rod end Left thread part# 809190 Quan. 2 3/4" 16tpi https://quartertonparts.com/ M38 Tie rod end Right thread part# 809191 Quan. 2 3/4" 16tpi https://quartertonparts.com/ Weld in threaded insert 3/4" 16tpi Left thread X 1" OD Quan. 2 Weld in threaded insert 3/4" 16tpi Right thread X 1" OD Quan. 2 Jam nut 3/4" 16tpi Left thread Quan. 2 Jam nut 3/4" 16tpi Right thread Quan. 2 1" steel tubing Edited by Barry S - 26 May 2023 at 2:54pm |
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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Here is a short video of all the steering system mechanics working.
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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So at this point the date was May 6. I had a working steering system but the Spring Willys Reunion wheelin day was on the 18th - only 12 days away. Now it was time for the unusual part of the project!
This is an electric power steering pump found in 2004 - 2013 Volvo model S40,V50, C30, and C70 model cars. $169.00 on E-bay. It would become the hydraulic power source for Grasshopper's power steering rather than try to run a power steering pump directly off the L-134 Go Devil engine. My L head is way under powered as it is. With only 80psi compression it needs a rebuild which will eventually be another off season project. In addition, I have lockers front and rear and large 750 x 16 tires which makes it extra hard to steer when stopped on rocks. I did not want to add the sudden extra temporary load on the engine for power steering just as I'm already asking the Go Devil to give all it can. I know that all the power ultimately comes from the engine but by pulling the extra power that is stored in the battery for those short bursts of extra ooompf should let me get all the power I can to the tires and still have power to steer. The engine will then replace the power back into the battery gradually as I drive. In addition I thought it would be easier to hide the electric pump out of the way and in general be easier for me to figure out how to install. I know that drift car guys use this exact electric pump because they tend to burn up engine driven pumps at high RPMs. Some times they even mount the pump in the trunk. They are all running rack and pinion though and I did not know how this pump would work with a Sagianaw box. I have only crossed paths with 1 other Willys guy who tried this idea but he used an electric pump out of a Toyota MR2. He said it worked great. Bottom line is that this was a total experiment and at the time I did not know if it would even work. Before anyone starts flaming me here I can tell you now that it is done, it works great! I ran it at Southington Off Road Park with the Willys Reunion guys and could not be happier. This whole writeup is simply me trying to give back and help other Willys fans. Next up: The install. |
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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If you source a pump used, make sure it has the special electrical plugs and long enough leads attached to be able to splice.
I decided to mount my pump behind the passenger side fender. I used part of the original pump mount so the pump would still be on the rubber insulators to cushion it and keep it quiet. Here are the mounting brackets I made. Test fit. Brackets welded in. Mounted in place. View from underneath with fender back on. |
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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dasvis
Member Sponsor Member Joined: 07 Sep. 2019 Location: Salem, Oregon Status: Offline Points: 1544 |
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Slick!
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1947 CJ2A #88659 "Rat Patrol"
1953 CJ3A #453-GB1 11266 "Black Beauty" 1964 Thunderbird convertible ..... & one of them moves under it's own power!! |
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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Next up are the hydraulic lines installation. First off I have seen too many Saginaw power steering conversions where the grill was all carved up for the hoses. Early on in the planning stages for this project I saw an article where a company was making special low profile banjo fittings for the Saginaw hose connections. The company is Pure Choice Motorsports in Lake Havasu City, Arizona where I spoke with Gary. He was very helpful and set me up with their custom banjo fittings. The fittings abandon the inverted flair down inside the Saginaw box and the seal is made instead at the surface of the casting using single use soft aluminum washers. This requires that the casting must be flat and smooth for a good seal. To prepare the surface I first stuffed paper towel into the openings to prevent filings and grit from entering the power steering box. (Gary also recommended cotton balls.) Then I used a wide flat file to work both openings at the same time until I had a smooth surface completely around each one. I followed that up with a very flat diamond grit knife sharpening stone, and finally a piece of fine emery paper held under the stone. When done I sucked the debris and paper towel out of the openings with a shop vac.
By using the banjo fittings I only had to make a tiny notch in the grill. View from top With hoses installed. I made sure to use -6AN TPFE hoses and fittings. Regular AN hose is not rated for the pressures found in the power steering pressure line. I could have used regular hose for the return line but I found a kit with 20ft of hose and lots of fittings and used it for both lines. At the pump end I ordered a special fitting for the pressure line to go from the Volvo fitting to -6 AN. When I made the hose I put a 45 degree angle fitting there. For the return line I ordered a fitting that goes from -6 AN to 3/8" barb which went to a piece of 3/8" rubber hose that was still attached to the pump return nipple when I received the pump. I used a section of the hose that already had about a 45 degree bend in it and with a couple hose clamps the hydraulic circuit was complete. The parts I used for the hoses were: Banjo fitting Part# 11810 5/8-18 X -6 AN Pure Choice Motorsports https://www.purechoicemotorsports.com/ Banjo fitting Part# 11820 11/16-18 X -6 AN Pure Choice Motorsports https://www.purechoicemotorsports.com/ Volvo pump output adapter Fragola 491963-BL Black Size (-6) x 16mm x 1.5 FI Male Adapter Fitting Amazon https://www.amazon.com/dp/B009S5G6SI?psc=1&ref=ppx_yo2ov_dt_b_product_details20ft -6 AN TPFE Hose kit CNRAQR 6AN PTFE Fuel Line Kit E85 20FT Braided Nylon Fuel Hose (5/16Inch) Amazon https://www.amazon.com/dp/B09ZHPXNB9?psc=1&ref=ppx_yo2ov_dt_b_product_detailsReturn line to barb adaptor AC PERFORMANCE Black Aluminum -6 AN Male to 3/8" 3/8 inch 9.52mm OD Push On Barb Fuel Line Pipe Connector, JIC 6 AN6 9/16-18 Thread Flare Hose Barb Fittings Amazon https://www.amazon.com/dp/B078BHNWZK?psc=1&ref=ppx_yo2ov_dt_b_product_detailsEdited by Barry S - 27 May 2023 at 12:50am |
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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The electrical was easy. For the main power I used #6 wire. The pump motor pulls about 5 amps normally and up to about 60 amps under full load. I installed a 80 amp breaker inline.
There are 3 small control wires coming out of the other plug. The 2 that are twisted together are for can-bus computer control and will be unused. On the Volvo the car's computer decides how strong the steering should be based on speed. I read that some one has made a controller that would allow you make the pump speed variable. I just taped each one off. The 3rd wire is the trigger wire that turns the pump on. When energized by positive 12volts it starts the pump after a 3 second delay and runs it continuously at 70 percent. I wired it through a toggle switch on the dash. That allows me to turn the power steering on or off as I want. Here is a short video of the power steering system 1st start up. Here is the circuit breaker I used: Erayco 80 Amp Circuit Breaker with Manual Reset for Car Marine Trolling Motors Boat ATV Manual Power Protect for Audio System Fuse, 12V-48VDC, Waterproof (80A)Edited by Barry S - 27 May 2023 at 12:10pm |
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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With only 1 weekend left before Southington I still had a lot left to do. When I set the length of the tie rod I had spun each front tire holding a piece of chalk against it and measured to the chalk lines at the front and back of the tires to make them parallel. After completing the tie rod I needed to set the toe in and figured I'd use the chalk lines. Turns out that the toe in should only be about 1/16" and the chalk lines weren't accurate enough.
I jacked each front tire slightly off the floor and scribed a fine line into the tires with a screw ran through a piece of wood. Then I put the Jeep back on the floor and adjusted and locked the toe in. |
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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Barry S
Member Joined: 01 Mar. 2020 Location: Ohio Status: Offline Points: 660 |
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I had to make sure that nothing would interfere after the tie rod flip so I jacked each side up to full stuff and turned the wheels to their limits each way.
I determined that I would need 2 1/2" bump stops in case the axle ever moved up any farther. I couldn't find exactly the size I needed that had 4" bolt spacing so I got some polyurethane ones from Amazon that were less than 2" and made spacers out of a leftover piece of composite deck board make up the difference. Universal Bump Stop Leaf Spring Bumper Set 9.9137G Fit for Many Cars, Trucks and SUVs, and for 1976-1983 Jeep CJ5 & 1976-1986 Jeep CJ7 |
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1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729 194? CJ2A 04893/194304 1946 CJ2A 46745 1946 CJ2A 36723 1945 MB 413665 1971 CJ5 8305017 375392 Drive train parts donor Bantam Trailer T3-C 25487 |
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