Re: Restoring Rusty
 

Where the heck did you come up with that bread technique? I've always packed grease behind the bushing to push it out.

Re: Restoring Rusty - Flywheel
 

next up was the brand new $75 dollar flywheel

a little carb cleaner to wash off the grease (I find myself currently in between brake cleaner, ie I'm all out or I would use it)

a little blue locktite on each bolt

and she's on

Re: Restoring Rusty
 

at some point I cleaned the frame rails a bit, got all the loose gravel off of them, and wiped them down with some mineral spirits

anybody know if the transmission cross member is supposed to come out, I would love to remove it so I can paint it

Re: Restoring Rusty - New Clutch
 

then it was time to put on the clutch, I have never installed a clutch before so I was really looking forward to this part, I couldn't wait to use the center plastic clutch tool, like the big boys do on all the car shows, that was so cool

also used some carb cleaner on the pressure plate to wipe off the grease they put on for storage to prevent rust

can't wait to try this normal diaphragm clutch, should be much more like a car clutch I hope

Re: Restoring Rusty - Clutch Fork
 

managed to remove the clutch fork out of the bell housing, I tried it at night the first time and couldn't see what was holding it in, so I tried unscrewing that hex bolt which I recon is there for adjustment purposes, anywho in the daytime I realized I can just hammer it out and it slips right out

same goes for the throwout bearing just tap it out

do you see that notch in the old bearing, that don't belong there does it?

Re: Restoring Rusty
 

Re: Restoring Rusty
 

LOL, it's what my grandpa would have shown me had he had a truck and knew how to work on it, JK - some forum, but you can YouTube it

Pilot Bearing Vs Slice of Bread

https://www.youtube.com/watch?v=dfDV982g4XM

... and you thought I had no skills

Re: Restoring Rusty
 

i been watchin this from day 1 and wish i did some of the fix on the go with my truck but she needed to much love your doing a great job if only you were closer id have given you the new clutch for my sm465 but im glad im not the only guy cuttin the crust off my samiches

Re: Restoring Rusty
 

You da man.

Re: Restoring Rusty
 

Greg, that's a pretty funny (haha) technique with the bread. Seems to work though. I just shoot my grease gun into the recess.

I don't know why there's a notch in your old throwout bearing, but you shouldn't need it. One thing; check the direction sheet that came with the new clutch parts. The bearing can be put on the clutch fork two ways, but only one of them is correct.

Re: Restoring Rusty
 

spent some time cleaning what turned out to be Belle Housing... I guess princesses gotta live somewhere

let me take you on a little trip down memory lane as we remind ourselves what this thing looked like originally

Re: Restoring Rusty
 

I'm not sure how you got that bellhousing so clean.....Geezzzzzz.

Re: Restoring Rusty
 

That bell housing looks great! Are you going to clean up the transmission next?

How about some paint on these parts?

Re: Restoring Rusty
 

ooohhh, Purdy and shiny!

Re: Restoring Rusty
 

Dang...

Re: Restoring Rusty
 

Thank you, I am very proud of myself as it was very dirty and the stuff was literally caked on there.

Actually I will do the clutch linkage next, fork and the bellcrank ie Z-bar, as I work my way back from the front of the truck to the rear in reassembly. Then the transmission and drive shaft last.

I believe the bell housing was originally Chevy orange (not a fan) I kinda like it natural aluminum, but some sort of clear coat wouldn't hurt, any advice on what to use?

Would love to rub some gray POR15 on the transmission eventually but am low on funds.

The drive shaft is getting a semi-gloss black POR15 treatment since I have some left over from when I painted the frame rails.

Re: Restoring Rusty
 

That's what I said! Turned out nice, real nice.

Re: Restoring Rusty
 

I would polish it with Simichrome and a buffing wheel, and leave it at that. Used to do that all the time on motorcycle cases, triple trees, etc. The bikes with coated aluminum always looked like garbage after a couple years, because it is very hard to keep a clear coat on aluminum, and they would chip and flake off. Looks awful.

Here's what polished bare aluminum looks like.

http://belmontcycle.com/yahoo_site_a...115842_std.jpg

Re: Restoring Rusty
 

Thanks Rich, I will look into that, I was wondering about some sort of protection coat on the account that I thought aluminum from the factory comes with something on it, more importantly is that your Norton?

Re: Restoring Rusty
 

Nah, that's just a picture I found on the net.

Mine's an 850 Commando.

http://www.walmart.com/ip/37811052?w...362295&veh=sem

Re: Restoring Rusty
 

and the belly of the bellhousing...

Re: Restoring Rusty
 

ordered some parts for the clutch linkage,

needed a fork return spring (mine was broken) and yes there are two there a long and a short one, my long was was broken

got a new rubber boot for the fork

and a Z-bar rebuild kit, ie plastic bushings that hide inside there, mine was missing the one on the side of the bell housing - no bueno

Re: Restoring Rusty
 

clutch fork boot, old and new one side by side

Re: Restoring Rusty
 

so finally after six months figured out what this mistery "exhaust pipe" LOL spring was

it's actually a bellcrank ie Z-bar spring, two attach to it one short one and one long one, one side was already broken, and it was so brittle I broke off the other end trying to remove it off the frame rail

Re: Restoring Rusty
 

Re: Restoring Rusty
 

I see whats next for your truck Gregski ;) Those front shocks look like the OEM shocks that have been in place since that truck went down the assembly line.

Re: Restoring Rusty
 

Yup, that is definitely on the list, the plan is to lower the truck at the same time

Re: Restoring Rusty
 

Nice work Gregski, love watching the progress of the truck. Makes me want to get out and work on mine, come on spring!

Re: Restoring Rusty
 

I swear it looks like you use a sandblaster on those parts. Too darn clean.

Re: Restoring Rusty
 

Man, I wish.

Re: Restoring Rusty
 

cleaned up the fork and painted it, being careful not to paint the tin clip in which the bearing spins

not my best cleaning job, but it will do fer gobermint work

Re: Restoring Rusty
 

also avoided getting paint in the ditch where the ball joint fulcrums

Re: Restoring Rusty - Z-bar
 

next up to get cleaned up and a coat of paint was the beelcrank aka the Z-bar

I was careful not to get any paint inside the hollow tube, nor on the grease fitting

Re: Restoring Rusty - Z-bar
 

Good job!

Re: Restoring Rusty - Z-bar
 

Thank you, I'm trying but right now it's like sinking in quick sand on this job, though I am learnin'

Re: Restoring Rusty
 

so this Z-bar, well that's more than just a hollow pipe I tell you, there's quite a bit of engineering that goes into this rascal, literally

doing a clutch job where you replace the fly wheel, pilot bushing, clutch plate, clutch pressure plate housing, and throwout bearing, and not going the extra mile to take care of the 40 year old linkage is like quitting a marathon on mile 25

so when I peaked inside my Z-bar formerly the bar known as the bellcrank, I noticed right away it was missing a plastic bushing on the clutch side (white piece second from the left in the picture was missing originally) metal on metal didn't make for the smoothest of actions, it actually wore a groove in the pipe (I might could replace the entire Z-bar, we'll see), add to that dried up grease, dust, and rust, and kiss your smooth action good bye, so... I went out and bought some replacement plastic bushings and these silly felt gaskets, third piece from the right (pretty worthless universal junk)

so here is my attempt at breaking down it's anatomy (pretty much all there except I am missing what I call a star washer in front of the bolt on the far right, space left open)

Re: Restoring Rusty - Clutch Pedal Disassembly
 

Re: Restoring Rusty - Brake Pedal Disassembly
 

well as luck would have it you can't take out Mrs. Clutch Pedal without hearing it from her neighbor Mr. Brake Pedal, after all it's like they're joined at the hip, they share the same long bolt which they pivot on, you want clutch pedal, you get clutch and brake pedal FREE of charge, LOL

so here's the anatomy of the brake pedal, pretty much same prognosis, we need new plastic bushings and a lots of cleaning

Question for anybody reading: What do we use to lube up the metal pivot sleeve and them bushings, what type of grease?

Re: Restoring Rusty - Brake Pedal Disassembly
 

Lubriplate lithium grease. Stable over a very broad temperature so you don't have the clutch and brakes work differently when it's cold versus when it's hot. Excellent for metal on metal, metal on plastic/nylon bushings, roller bearings, etc.

http://www.skygeek.com/lubriplate-63...4-oz-tube.html

Re: Restoring Rusty - Brake Pedal Disassembly
 

Rich, thank you so much, not only do you take the time to help but you include links to get to the item you describe, how awesome is that.

My turn....

http://i.istockimg.com/file_thumbvie...er-bottles.jpg