1979-1993 & 94 Conv [Subscribe to Daily Digest] |
Sounds to me like you have all of the relevant hardware.
You are correct in that the deep dished side of the pulley gets pressed onto the shaft first. The shaft splines will fit into the pulley splines, although it is tight. A good way to do this is to clean both the splines, apply a little oil, and throw it into a bench vice (cover the jaws with something soft like wood) (also thread one of the wiper nuts onto the end of the shaft until it is just flush with the top of the shaft, this way when you use the vice you won't flare the top of the thread.) Make sure you get the shaft into the vice square and push straight. Push until the shaft sticks a little way out the back of the pulley, like 1/32". A good way to check this distance before drilling the hole is to assemble all of the bits together, stick it through the frame bushings, and temporarily install the clip. There should be a smidgeon of axial play in the shaft. This allows the wave washer to slightly preload the o-ring and stick the nylon washer up against the face of the frame.
The easiest way to drill the hole through the pulley and shaft is with a drill press, (although it is quite possible using a hand drill, a steady hand and a sharp drill bit). Either way, I would pull the clip on the top of the shaft off, remove all the little washer bits and do the work on a bench. (The vice would be nice for this too if you opt for the hand drill.) You can either push in a spring pin or a cotter pin, the objective is just to keep the pulley from sliding back off.
Now armed with your refurbished pulley/shaft assembly, drop on the wave spring washer, next the nylon washer. I usually use some white marine lithium grease on the shafts. Slide the shaft up through the frame bushings, drop on the o-ring, and then the cover washer, and finally install the clip.
Now comes the fun part. The little cable has a crimped metal bit at one end, a crimped metal bit in the center and a crimped on thread at the other end. The unthreaded bit on the end drops through and locks into the opening in the linkage a couple of inches from the end. The cable then goes under the pulley, around over the top and heads back over to the end of the linkage. The mtal bit crimped in the center of the wire sits into the notch in the pulley. The threaded end is pushed out through the hole in the end of the linkage, and the tensioning nut in reinstalled. Now there are two tracks in the pulley. You can probably tell by the wear patterns where the cable sat during its previous life. Anyway, because the cable wraps the pulley 360 degrees, the cable must sit in the two different tracks.
By the way, all four of the mounts for the assembly into the car should have had the rubber bushings with the little metal insert. At least all of the ones I have taken apart had them.
Hope this helps, and if I missed something just let me know.
posted by 68.1.17...
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