M416 Build in Maryland

[Kflash]

Still awake and needed to put the new lunette on. I had ordered a new spring, but it ended up being to short. To get the manual suggested .01 feeler gauge to slide between the coils, I would have had to tighten past the cotter pin hole completely. Hmmm! Spent $15 on that new spring! O well, used the old one and it is all in good order.

In preping for the new chains, I fought to take out the 6" bolt that holds the whole front assembly on. Wow was that a bear. Hate working with rusty bolts. It is a lock nut, so made it more difficult. Heading to Fastenal after work tomorrow for a new bolt and nut.

Good night!

[Mark Harley]

I ditched the huge military hooks and safety chains too.
I went with safety cables that recoil some when hooked to the truck.

[Kflash]

I need to make sure that I don't over spend out of excitement. Plan this out slowly. I did see the metal tops produced by Siera 4x4. Pretty committed on a roof top tent!

A Fastenal is located on my commute to work. A quick stop there and I walkd out with the 5 1/2" x 3/4 grade 8 to replace the one from last night's insomnia.

[Kflash]

I need to make sure that I don't over spend out of excitement. Plan this out slowly. I did see the metal tops produced by Siera 4x4. Pretty committed on a roof top tent!

A Fastenal bolts warehouse is located on my commute to work. A quick stop there and I walkd out with the 5 1/2" x 3/4 grade 8 to replace the one from last night's insomnia.

Lunette.jpg New bolt.jpg


Though tiny little screws, the two that hold the drain plug retainer in place are rusted solid. Probably end up taking the dremel to them. Any thoughts on these? Maybe try needle nose vise grips first? Would leave them alone except the rubber stoppers are shot. Bought new ones off Ebay!

drain plug.jpg

[Kflash]

I ordered a set of original M416 lights from another Expedition Portal member - thanks! Once I get them sorted out, I will be installing those. Though I hear they aren't that bright and have no side markers, they just plain look cool!

For now, I have a set of LED tail lights that I found on sale.

M416 Tail Lights.jpg Trailer lights.jpg

Question of the evening. I haven't pulled one off yet to see for myself (saving that fun for bearing/race replacement this weekend). What are the collars for under the lug nuts? Is this a two piece unit or just one weird nut?

lug nut.jpg

I picked up a few new grade 8 washers to replace those on either side of the shock buskings and a few new cotter pins. That's it for tonight.

[Kflash]

Well, Friay the 13th got me. Went to a BBQ at a friends house. After about 4 hours, we were getting ready to head home. Key in ignition of the Jeep, turn and nothing. Not the battery. Heard a continuous clicking from the fuse box. one of the relays. Pulled the start run relay and the clicking stopped. May or may not be the relay. No other signs that this was going to happen, just died.

Ended up having it flat beded to the Jeep Dealership for service on Monday. I have the lifetime powertrain and extended warranty, so hope I'm not overly shafted with "what they find to be the problem"!

Anyway, roll with what comes your way cause there ain't anything you can do about it.


Good day for the trailer.

Was able to pull the hubs and replace the races and bearings. I had picked up a race seating kit from Harbor Freight that made the races go in smoooth! Actually, the bearings all looked good. They must have been repacked at some point with the amount of grease still in there.

packing bearings.jpg Hub install.jpg

New NAPA shockes went on. The originals were SHOT! There was absolutely no life left in them. Completely floppy.

New shocks.jpg

I ordered a new canvas cover off Ebay. Really heavy duty and seems impregnated with some sort of weather proofing. New tires and rims look great. This thing is all business!

Finished side.jpg Front angle.jpg

Only thing left is to repace the tail lights. I am waiting on a set of original lights to redo. Here is the project to date. At some future time I'll do a more extensive restore, but this gets me a trailer for now. Maybe a good winter project! Need to save for metal cover and roof top tent.

Now if I only had the Jeep to go out for a test ride/tow!!!! Once it is back, I'll determine if I need to put some lift shackles to level it out. I am going to hold out on the axle flip for the next phase.

[Mark Harley]

Looks very nice. Good that the jeep died in town and not out in the bush.

[Kflash]

Looks very nice. Good that the jeep died in town and not out in the bush.

I know! Of all the places...parked safely in a driveway. If at work earlier that day, I'd have been on the 4th or 5th floor of a parking garage!

[Kflash]

before restore 3.jpgbefore restore 1.jpgbefore restore 2.jpg

[DonBeasley]

It is looking great. You have made a lot of progress. Mine is 2 years old now and still going slow.

I vote for the axle flip. You can do it in one evening.

Sierra 4 x 4 did my lid and it is great. I spent more on the lid then I did on most of the trailer but in the long run it has been worth it.