I ran out of time to get the new Jeep ready to take to the rally. In order to take this one, there were a couple of things that I had to get done. For one, I never finished installing the military fuel pump. The other thing was to adjust the valves since it was pretty noisy (compared to the “new” Jeep) at last year’s rally.
To finish up the fuel pump install, I had to bend and install the 5/16 x 20″ vacuum line and 1/4 x 20″ vacuum line that I bought the last time I was working on it. The 5/16″ line is the “S” shaped line that runs from the back side of the fuel pump, over the top and curves around to the main vacuum line block at the front of the engine. I tried a 12″ line the first time, but needed 14″. They don’t sell a 14″, so the next size is 20″! It was a pain working with all of that extra material, but I got it done.
The second line was the 1/4″ one that runs from the bottom side to the wiper line tee. 20″ was the perfect size.
I only adjusted the intake valves because they are easy to get to, made the most noise, and I didn’t have a replacement gasket. They were set at around .018″ which is factory setting – too noisy for me, so I adjusted them to .015″. The other Jeep had them set at .014″. I removed the plugs and used my compression gauge to find TDC, and painted the notch in the pulley so that I could see it easier. I adjusted them in order, then went back and double checked.
After I put everything back together, I had to go pull the batteries out of the other Jeep. I went ahead and serviced them while they were out. As soon as I fired it up I could tell that it was much quieter! I pulled out of the shop and went for a ride.
I drove around for about 10 minutes and as I was pulling into the driveway, the car behind me blew their horn! I knew this could mean one of two things – either they were saying “wow, cool Jeep!”, or something was wrong. When I pulled up at the shop, I used my trusty old brake pedal holder (a 1x6x24″) to hold the brake pedal down while I checked the brake lights – THAT was the problem! I did a little troubleshooting and finally used my 1″ socket and long extension to remove the switch. I checked it with the continuity tester on the multimeter – it worked intermittently. In order to get this thing finished up, I went ahead and pulled the one off of the other Jeep for the time being. It was a PITA to get off because the rubber boot was larger than the switch body and the socket wouldn’t fit over it. I ended up using some 4″ vise grips to loosen it because that is all that would fit in the space. I checked it with the multimeter before I installed it – PROBLEM SOLVED! I’ll order a new one if I can’t find a good used one at the rally.
I took it for another test drive (after checking it’s function with the brake holder) and put it up until Monday. I’ll give it and the truck a bath then, since that will be my last day off before the rally.