Project Slowly Underway: Berrien 295

[vanapplebomb]

I cleaned up a pair of E-brake cables. I had three sitting around. One of them was cracked where the flexible part meets the angled metal end that fits into the backing plate. Another one had a cable that was fraying apart under the spring near the hook on the brake end of the cable. The solution? Cut the cables off at the treaded end so they can be pulled out of the tube, swap the bad cable for a good one, grease the cables, then slide the cables back into the tubes. I didn't need the threaded ends because the cables will need to be shortened for the buggy anyways.

I will post up some pictures of this weeks magic when I get around to uploading stuff.

[vanapplebomb]

Here is my short documentary on E-brake cables. As I mentioned earlier, I had three cables, two of which were damaged. One, the tube separated from the curved metal end that fits into the backing plate. The other broken one had a cable that was fraying apart...





Since the cable in the broken tube was fine, and the cable in the good tube was broken, I swapped parts. I knew I was going to have to shorten the cables for my buggy, so I didn't feel to bad cutting off the threaded end. Once I cut the ends off, I pulled out the cables. I greased the good cable and slid it into the good tube. Then I re-greased the other cable and tube I had that there was nothing wrong with. A little lubrication never hurts.






After reassembling both cables I took them to the grinder, and with a 6" wire wheal, I cleaned up the exposed metal parts. Then I shot them with a couple coats of paint to help ward off corrosion.

[vanapplebomb]

Earlier this week I picked up a large shaft worm and sector steering box. Turns out the box was made in '59. The shaft turned and the exterior seamed to be in ok shape, but it was obviously in need of some TLC.





I started stripping down the steering box by removing the drop arm and the toasted coupler. In the process I had a big red flag pop up. When I removed the lower stud beneath the gear box, no oil came out. Hmmm...





After removing the cover I found this disaster...now I know why a 53 year old steering box wasn't weeping a single drop from either of it's seals. There was not a single drop of oil in the box. This is what the result of more than a few years of neglect looks like.

[vanapplebomb]

Despite looking like a lost cause, I think that it will work ok after a good cleanup. Well, time to rip the rest of this guy apart...First up? The sector shaft! It is a tight fit, and takes some force to remove if from the housing. After removing the sector adjusting pin and spring, I used a punch to drive the shaft out from the bottom of the box. Note that the shaft assembly is two pieces, a ball with teeth cut into it, and a shaft with a socket in which the ball fits.






After the sector shaft was removed I pulled the worm shaft and adjustor. Removing the pinch bolt allows the adjustor to be pulled out of the box. Again, it is a snug fit, and some force had to be used. The box was pushed off the adjustor by smacking it with a hammer and punch.





The adjusting thrust ball bearing came out on the worm shaft (Note that this is the bearing the adjustor pushes on to take up the slack in the worm shaft [see second picture]). The opposing thrust ball bearing pressed in the housing was driven out with a socket.

[vanapplebomb]

Next the seals were removed. The small seal was driven out of the adjustor with a socket and punch. The large sector shaft seal was removed with "the drywall screw trick." I have always found that to be the easiest way to remove larger seals. Just drill a couple small holes in the edge, screw in some coarse drywall screws, then pull the seal out by prying on the heads of the screws.

[vanapplebomb]

With the box completely taken apart, it was time to give it a much needed bath ;D

A 6” wire wheel on a grinder did a good job of taking off most of the surface rust from the ferrous parts. I was also able to do the majority of the cover with the wire wheal. I had to small use a wire bush to clean the insides of the box and wherever else the wire wheal couldn’t reach. A lot of work? Yeah, but I find it fun believe it or not. Anyways, yeah, once those parts were brushed up I shot them with brake cleaner to remove the oily residue and wash away any grit left on them.

[vw1s]

Where did you get that steering box? What a piece of junk! ;D I hope you didn't pay too much for it! ;D Good job with the clean up!

[vanapplebomb]

Thanks for the compliments Patrick! As far as who sold the piece of junk to me...I think his name was Patrick??? Well, whoever it was, they gave me a fair deal for a mystery box, hahah. It's not a lost cause. I think once this thing gets put back together it will work just fine.

[vanapplebomb]

One thing about the steering box struck me as odd. This...




The input shaft had a seal, the sector shaft had a seal...no seal here though...I figured that maybe this was the culprit for the complete lack of lubrication. There was no seal or plug to keep oil from draining out behind this bearing. I posted the picture on TheSamba in the 53-57 beetle forum. Turns out there is supposed to be a press in metal plug that fits into this bore to keep the oil in. A Samba member was gracious enough to offer to ship me one. I guess we will see when I get it though.

At any rate. I think project updates will slow up for a couple months. College started back up so I will be away from my projects. Guess that just means I will be reduced to asking lots of questions again ;D

Thats ok. Questions are good. I love learning new stuff from people much more knowledgeable than myself.

[MadMike]

Hey Dirk,Can't wait to see you tackle a Transmission or a Motor ;D ;D ;D and quit playing around with the little stuff ;D ;D ;D ;D ;D ;D ;D

[vanapplebomb]

Hahaha, yeah, you wish Mike ;D


As much as I would love to do that sort of thing, I just don't have the tools to get the job done. Too bad, because it sure looks like fun. I certainly wouldn't mind spending an evening with someone tearing into and rebuilding an engine or transmission. That would be really cool.

[MadMike]

That can Happen ;D "Come on Down' ;D ;D ;D u bring a motor or trans and we can split it ;D ;D ;No evenings I'm a morning person

[vanapplebomb]

Mike, that would make my day!!! My last day of class is May 17, so after that I will be back down state for a couple months. I would enjoy opening up my gearbox with you. Everything seems to work fine...but maybe you could take a look at this...reverse gear right? Looks like the previous owner liked to shift into reverse before the car stopped rolling.

[MadMike]

Dirk,I'm on dial-up all I see are little boxes ;D

[vanapplebomb]

I miss my camera .... ... ... ... ... ...