Lorrie Van Haul - 1967 Dodge P200 Mail Van

Hey All,
My name is JC Allison, 70 years old, and the caretaker of Lorrie Van Haul, a 1967 Dodge Mail Van which I bought in 1975. Lorrie has been in suspended animation since 1996 due to MY health problems, and she is well on her way to being reawakened. Lorrie's Engine is a 225 Slant Six that was rebuilt in 1985, and has 25,000 miles on the rebuild. She has right-hand steering, all Stewart Warner Gauges, a Suburu Bucket Seat, Wagon Wheels, and big tires. She has a Diamond Deck Plate Front and Rear Bumpers, and a 14 Gauge Sheet Metal Roof with End Plates. For JPGs of Lorrie, click here:

http://msamericanpi.bravehost.com/dodge.htm

So far, the process of reawakening Lorrie has included: Have installed a NEW Water Pump; Fuel Pump; Front Brake Cylinders; rebuilt her Holley 1920 Carburetor;  obtained a NEW Master Cylinder; had her Radiator serviced; and am at present working on her Right Rear Axle and Brake. When finished with the Right Rear Axle and Brake, will be rebuilding the Left Rear Brake; installing the NEW Master Cylinder, and bleeding the entire Brake System to make it work properly.

Lorrie has a Differential Lubricant Leak on her Right Rear Axle, and so she is going to have her Right Rear Axle pulled, and a new Inner Seal installed. Her Rear Axle is an 8.75 unit, and with the Axle out, the Bearing will be checked for wear, and replaced if it is found to be worn out.

QUESTION: How does one ascertain if in fact a Bearing is worn out?

So far the education on Lorrie's 8.75 Rear Axle has included the details that the Inner Seal is meant to keep Differential Lubricant from getting into the Axle Bearing, and that the Outer Seal is to keep Bearing Grease from getting into the Brake Drum. And the fact that Differential Lubricant is getting into the Brake Drum is not necessarily an indication the the Outer Seal is defective.

QUESTION: Is this true?

If it is, I'm hoping that replacing the Inner Seal, and then carefully adjusting the End Play in the Right Rear Axle to 0.013" will solve the Differential Lubricant leak problem.

QUESTION: Am I being overly optimistic?

Some time ago, I did a Google search for "1967 Dodge P200 Mail Van" and found a reference that said: "This marque is thought to be extinct." But I have one.

Also, I have another VERY rare vehicle: Ms. American 3.14159, a "1964 Ford Galaxie 500, 4-Door, Hardtop, Fastback, Police Interceptor", the ONLY one that Google finds if you do a Google search for the above quoted search words.

For JPGs of Ms. American 3.14159 click here (have done much work on the 3.14 and she is in much better shape now than when the JPGs were taken):

http://msamericanpi.bravehost.com/galaxie.htm
http://msamericanpi.bravehost.com/galaxen.htm
http://msamericanpi.bravehost.com/galaxca.htm
http://msamericanpi.bravehost.com/galaxre.htm
http://msamericanpi.bravehost.com/galaxpa.htm

Anyway, hope this finds you all doing well, and thanks in advance for any information regarding the questions asked above.

JC  
Lorrie Van Haul - 1967 Dodge - P200 Mail Van - 225 Slant Six - Automatic Transmission - Right Hand Steering

Hey All,
Am doing the research on where to get the two Brake Support Gaskets for the Right Rear Axle Inner Seal Replacement.

So far Auto Zone and NAPA have nothing listed for them.

QUESTION: Are these items that may have to be hand made?

They probably wouldn't be all that hard to make as there is the Retainer Plate to use as template.

Any Suggestions

JC  
Lorrie Van Haul - 1967 Dodge - P200 Mail Van - 225 Slant Six - Automatic Transmission - Right Hand Steering

Hey All,
This is Lorrie's Right Rear Axle:



Lorrie's Right Rear Axle was taken out of the Axle Housing earlier today. It did NOT require a Slide Hammer to remove it. The Nuts were taken off the the Studs holding the Retainer Plate against the Brake Back Plate, and the Axle came out really smoothly. This JPG shows end of the Axle Housing, and the Inner Seal which is pressed into the end of the Axle Housing:



The Inner Seal has to be removed and replaced. It is in there REALLY tight. Am going to have to obtain a Slide Hammer with hooks facing outward to go into the center of the Inner Seal and pull it out.

This JPG is of the Right Rear Bearing Assembly on the end of the extracted Axle. It has been cleaned up a bit, but will be better cleaned before being reinstalled:



The shiny area on the left is the place where the Axle turns in the Inner Seal. The piece to the right of that area is the Collar, and it is pressed on and is tight. To remove it, one has to cut it off with a Cold Chisel! I don't plan on removing it. To the right of the Collar is the Bearing Cone containing the tapered Roller Bearings. To the right of that is the Bearing Cup. It is this part that can move to the left to tighten the Bearing or to the right to loosen the bearing. The threaded area the right of the Bearing Cup is the Adjuster that threads into the Retainer which is the part with the Bolt holes in it. It is this Adjuster that tightens and loosens the Bearing. The bearing itself is smooth and has no grinding sounds or feelings. The Bearing seems to be fine.

This next JPG is of the Bearing at its loose-est:



This next JPG is of the Bearing at its tightest:



This next JPG is of the Adjuster at its loose-est position (threaded almost all the way out of the Retainer Plate):



This JPG is of the Adjuster at its maximum tightened position (threaded almost all the way into the Retainer Plate):



And this LAST JPG is of the Keeper that is holding the Parking Brake Cable in place.



Last things first: The Brake Back Plate will NOT come off of the Studs that are holding it in place unless the Parking Brake Keeper is taken off to let the Parking Brake Cable permit the Brake Back Plate move far enough to clear the ends of the Studs.

QUESTION: How is this Keeper removed?

The Brake Back Plate HAS to come off to put a new Gasket between the Back of the Brake Back Plate and the Axle Housing Flange.

Anyway, tomorrow will find Lorrie's Right Rear Axle going to the Livingston Auto Zone for the Inner Seal and Gaskets. And while there will see if I can either borrow or buy a Slide Hammer Seal Puller.

As you can see, things are moving right along here. Am still not totally and absolutely clear on how the Bearing Adjustment Mechanism works, but the first understanding is that there is a part in the Differential that is in contact with the inner ends of both the Right and Left Axle Shafts, and the Adjuster, when it is tightened, pushes on Right Rear Bearing Cup forcing it further over the Right Rear Bearing Cone effective tightening the fit of the Bearing, and the Right Rear Bearing Cone, pushes on the Right Collar, which pushes on the Right Rear Axle, which pushes on the part in the Differential that pushes on the inner end of the Left Rear Axle, which causes the Left Collar to push on the Left Bearing Cone forcing it deeper (tighter) into the Left Rear Bearing Cup which can't go any further to the Left because it is held in place by the Left Rear Retainer Plate.

If the End Play is too loose, it permits the Bearing to be loose, which allows the Axle to move up and down under load, which distorts the Inner Seal allowing Differential Lubricant to seep past it, and then it gets through the Outer Seal which is meant only to keep Bearing Grease from getting into the Brake Drum. And THAT is the condition that Lorrie is experiencing.

Will install a NEW Inner Seal, and then adjust the End Play to 0.013" and that should solve the problem.

Hope this finds you all doing well.

JC  
Lorrie Van Haul - 1967 Dodge - P200 Mail Van - 225 Slant Six - Automatic Transmission - Right Hand Steering

Hey All,
Thursday Update:

There is a saying... Something about the "Best laid plans of mice and men..."

Well, that applies here today. It was supposed to be SUNNY today, and RAIN tomorrow.

Now you'd think with all the berzillion watts of radar power that they'd be able to see heavy cloud cover, but "NOUUUUUUUUU!" (John Belushi)

So it has clouded over, threatening to rain, and so Ms. American is back under the tarp. No trip to Livingston today.

Instead, the trying of the "Old Indian Trick" to get the Parking Brake Cable Keeper back through the Right Rear Brake Plate was in order.

Alas, the topology of the Right Rear Brake Plate is such that one cannot get the Box End Wrench close enough to the hole to sufficiently compress the "tangs" on the Keeper. But not to despair... One can use a small Hose Clamp! And it works like a champ!

Anyway, the Keeper's "tangs" were compressed with a small Hose Camp just enough (except for one) to get it started through the hole, and that last tang was compressed with a pair of Needle Nosed Pliers, and with just a little fussing with it, it finally went back through the hole in the Right Rear Back Plate.

Then came the attempt to remove the Right Rear Back Plate from the Flange Studs on the Right Rear Axle Flange.

It took a bit of banging on it with a small Hammer, and it came off, though not without buggering up some of the threads on one of the Flange Studs, which are going to have to be repaired with a proper "Die"... That for those who are not familiar with the term, is the Female equivalent of a "Tap".

Nonetheless, the Right Rear Back Plate is sitting here on a table after having had at least 1/2" (in some places) worth the Differential Lubricant soaked Caliche' Mud that was caked on it removed with a Screwdriver and a Pallet Knife.

Next will come the cleaning of it with a large Wire Brush Wheel in an Electric Drill, followed by a small Wire Brush Wheel in the Craftsman RotoTool.

Once it is completely clean, it will get painted both sides with Low Gloss Black Rattle-Can Paint.

The Gasket that goes between the Right Rear Back Plate and the Axle Housing End Flange is METAL. It came off intact, and without damage. It originally had a coat of some kind of elastic material on both sides. Am going to use it as a template to make another Gasket out of some Composition Material to go between the front side of the Right Rear Back Plate and the Retainer that is on the Axle Shaft. Once THAT Gasket is made, both sides of the Metal Gasket will get a coat of NAPA Performix PLASTI DIP Multi-Purpose Rubber Coating, which will be let dry, and then the Metal Gasket will be ready for rinstallation at the proper time.

Checked on the Outer Grease Seal that is supposed to be in the Adjuster, and I'll be damned if I can tell if there is one there. The Adjuster doesn't appear to have any "radial" slop in it when trying to move it around on the Axle Shaft, so there HAS to be some kind of interior material inside it, but there is no way to see it without removing the Collar, Bearing Cone, and Bearing Cup.

Since the purpose of that Outer Grease Seal is to keep the Bearing Grease from migrating into the Brake Drum, and since the Bearing Grease is of such a viscosity that it doesn't migrate easily, there occurs this:

QUESTION: Is the function of the Outer Grease Seal of such import that it would be efficacious to replace it, seeing as to how THAT would entail the buying of a NEW Collar, a NEW Bearing Cone, a NEW Bearing Cup, and a NEW Outer Grease Seal, along with the expense of having the OLD Collar, OLD Bearing Cone, and OLD Bearing Cup removed, and the NEW components pressed on by a machine shop?

Anyway, once again the weather has put a crimp in the progress here. Am going to have to see what the forecast is to find out how long it will be inclement, not that much creedence can be put in the weather forcasts anyway.

Will be taking some more JPGs of the Keeper Mechanism that keeps the Adjuster from spinning out of adjustment, and other interesting items.

Hope you all are well.

JC  
Lorrie Van Haul - 1967 Dodge - P200 Mail Van - 225 Slant Six - Automatic Transmission - Right Hand Steering

Hey All,
Friday Update:

Cleaned the front and back of the Lorrie's Right Rear Brake Back Plate. It is ready to be wiped down with solvent, dried, primer applied, and then painted low gloss Black on the back side, and gloss Black on the front side.

The first JPG is what the Front Side looks like at this point:



The JPG is what the Back Side looks like at this point:



The cleaning involved scraping all the mud, grime, and etc. off with a Screwdriver, Exacto No.11 Blade and a Pallet Knife. It was then soaked in hot water and detergent, and scoured with a wire brush and Scotch Bright pads. It was then dried and given a going over with a Wire Brush Wheel in an Electric Drill. It was then detailed using a small Wire Brush Wheel in a Craftsman RotoTool. It came out looking pretty nice. It is nicely textured.

Will get JPGs of it when painted.

JC  
Lorrie Van Haul - 1967 Dodge - P200 Mail Van - 225 Slant Six - Automatic Transmission - Right Hand Steering

Hey All,
Sunday Update:
The Right Rear Brake Components are all cleaned, and those that get painted are painted.

The Inner Gasket that goes between the Right Rear Axle Housing Flange and the Right Rear Brake Plate, and the Outer Gasket that goes between the Right Rear Brake Plate and the Retainer are almost impossible to find, and so the decision has been made to refurbish the Inner Gasket, as it is a metal piece with a rubberized coating on it, and to hand-make the Outer Gasket out of a fiber gasket material using the Inner Gasket as a template.

And so the process is to remove the "some kind of rubberized coating" from the metal gasket.

That is some kind of tenacious stuff! Tried using a Wire Brush Wheel in the Roto Tool and all it did was melt and then recongeal. Tried scraping it off with a No. 11 Exacto Blade, and some of it came off, but a lot of it didn't. Let it soak overnight in a mixture of Lacquer Thinner, Xylol, and Brakleen. That bubbled some of it up so that it could be removed with the No. 11 Exacto Blade, but a lot of it still remained. It is now soaking in a layer of Strypese Coating Remover, but the can of Strypese had been opened, and it may not be any good any more. We'll see in the morning when the Metal Gasket will be taken out of the Strypese and the rubberized coating tested for removablilty.

Once the metal is completely cleaned, it will be given a coating of Plasti Dip on each side, and when the time is right, will be installed with Form A Gasket.

The weather has again turned GORGEOUS, and is supposed to stay that way for three or four days. And so first thing in the morning it is off to Livingston to either obtain or order:

Two Rear Wheel Cylinder Rebuild Kits;
One Rear Axle Inner Seal;
One Seal Puller (Slide Hammer?);
A Caliper;
A sheet of Fiber Gasket Material;
A tube of Form A Gasket; and
Depending on how well the Strypese has worked overnight, maybe another fresh can of Strypese.

All this along with the acquisition of some other items unrelated to the automotive endeavors should put me back home around 1:00 p.m.

Then depending on whether or not the Seal is in hand, the process of putting the Right Rear Axle and Brake back together will proceed. Am aiming at having it done by the end of the week, at which time will then proceed with the rebuilding of the Left Rear Brake Assembly.

When that is finished, will clean out the Rear Brake Hydraulic System and hook up the Wheel Cylinders, and then will come the installation of the Master Cylinder, and the bleeding of the systems will put the finish on Lorrie's Brakes.

Isn't this FUN?

JC  
Lorrie Van Haul - 1967 Dodge - P200 Mail Van - 225 Slant Six - Automatic Transmission - Right Hand Steering

Hey All,
Tuesday Morning Update:

Was in Livingston yesterday.

Couldn't find any rebuild kits for Lorrie's Rear Wheel Cylinders. The Bore of the Rear Wheel Cylinder is but 13/16", which the guys at every parts house in Livingston said seemed awfully small for a 3/4 ton Van, but I had the Right Rear Wheel Cylinder with me, and that was what it measured.

After looking at the Cups, and the Bore of the Wheel Cylinder, the consensus was that the Cups were reusable as they looked absolutely NEW. So if new ones can't be found, will rebuild these using the present Cups and Spring.

Returned the too large Grease Caps to NAPA, and found the proper sized Grease Caps at AutoZone, so Lorrie now has BRAND NEW Grease Caps on her Front Wheels.

Ordered the Right Rear Inner Oil Seal, which should be in today after 3:00 p.m. Will either go get it later today or Wednesday morning.

Found that I could "rent" a Seal Puller from AutoZone for $80.00 which isn't REALLY a rental fee, but IS refundable when the tool is returned, so it was more like a deposit.

The only Seal Pullers that were available were shaped like a "Claw Hammer", and would not work on this particular application as the Oil Seal is recessed further into the Axle Housing than the tool would reach. May have to MAKE a Seal Puller. Am contemplating how to do that.

Did get a nice Caliper from Lowe's.

So it is supposed to rain her this morning, meaning that there will be little gotten done, but the next thing that needs doing is to pull the Oil Seal out of Lorrie's Right Rear Axle Housing. Will have to figure out how to do that.

Will be doing the final clean up the Metal Gasket today even if it means carefully scraping its entire surface with an Exacto Blade. Will get a sheet of Fiber Gasket Material with which to make the Outer Gasket when the Inner Oil Seal is Picked up.

More updates when events happen

JC  
Lorrie Van Haul - 1967 Dodge - P200 Mail Van - 225 Slant Six - Automatic Transmission - Right Hand Steering