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408 viewsThe repaired pin in place. Thin plastic washer goes between the gear (front and rear gears) and the case.
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407 views
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Reference: Rear gear box, rear side.406 viewsRear side of rear gear box. Steel roll pin is 3/16" diameter by 1-1/2" long. This is where the crank handle connects. The zinc washer is 2" diameter with a 3/4" hole and is a tad thicker than the original one (I couldn't find a thin one). The grommet between the washer and case is 1-5/8" outside diameter (OD) and 1/4" thick so it's just slightly thinner than the original one.
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404 viewsSame duct, just took the picture from the left side of the Bus. Wrapping this duct is likely the most difficult of all the ducts so go slow and think. I know the pictures aren't a huge help but they give an idea. I'm sure there's more than one way to insulate this loop.
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402 viewsWhere I zip-tied the left side of the harness. It comes down near the radiator over-flow container (the pink bottle). Don't use the aluminum object to the left, that's the heat-sink for the coils!
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400 viewsHere's the VR (voltage regulator) information. This is what you need. I got mine for $3.15 at Norvac Electronics, Inc. You can also get it at Fry's. NTE1932, IC voltage regulator, positive 10-volts, 1-amp.
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Connecting the DRL LED array.400 viewsI used a hand drill with a 2mm drill bit (smallest I had) to carefully drill a pilot hole into the side of the relay box. The pilot hole is 7mm down from the top of the lip of the fuse/relay box. It's between fuses M20 and M27.
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399 views
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399 viewsThis picture and the next show that the corner is cut and folded onto itself. It's best to have over-lapping than a gap in the insulation.
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398 views
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397 viewsInside of forward gear and planetary gear mating teeth.
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397 viewsThe pin is missing. Looks melted...??? Without this pin set in the case halves the planetary ring rotates and doesn't allow the forward gear to rotate properly.
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Reference: Rear gear box, front side.394 viewsFront side of rear gear box. Steel roll pin is 3/16" x 1-1/4". This is where the drive shaft fits.
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393 viewsThe new pin in the hole, ready for welding.
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392 viewsAll the bearings are roller bearings and they are held in with the grease. When cleaning the grease and wiping the bearings they will most likely fall out so work over a soft, plush towel to keep them from bouncing away. Pack the bearings and cage surfaces with fresh grease and slip any fallen bearings back in. You should see no gaps between the bearings. Pack more grease in when they're all in and roll them around with your finger to spread the fresh grease around. It will hold them in there.
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392 viewsPermatex 2A gasket silicone is what I smeared on the mating surfaces of the case half instead of using a gasket.
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391 viewsShowing the path of the LED array as it goes down on the front part of the head light. That blue thing is simply a nylon auto trim tool I had laying nearby that I used to hold the fascia away from the head light so I could work with both hands. Now just apply power from the turn signal tap!
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390 viewsFog harness using a hook on the right side radiator fan surround.
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390 viewsSame thing for forward gear.
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Left side shown. Right is just like the left side.388 viewsAfter removing the bumper skin fasteners remove the 10mm bolt and pin retainer. Do this for both sides (remove all fasteners). This will allow the front fascia and bumper skin to be pulled back enough to get to the head lights. The bumper is still attached to the vehicle by lower fasteners but for this situation it doesn't need to be fully removed.
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