Operation 424 rebuild..

[Wheeler 2,275]

Spoiler

 

Well as some of you might remember, I have a spare Wide Open 424 kit. The cable got mess up, I temporarily fixed it but was never rite. I'm going to tear into it, make sure all the bearings, seals are good, no rust on the rods etc. I'll have to either locate another cable, have a shop make me one, or do a better job at repairing this one.. I'll post up pics once I get into it..

 

 

 

Edited November 16, 2022 by Wheeler

[Wheeler 2,275]

I’m going to order 2 bearings & seals. I’ll have a new cable fabed up as well. Then she will be good as new!!!

[_Wilson_™ 5,837]

Hey @Wheeler if you can make a video.....i like see the repair .........you've posted some videos before.... (Pics would be great as well)  Also i have a couple id like to post, nothing about a 424, but I've wanted  to post them for a while..... So I'll be asking you about posting a video @WonderMonkey told mean long time back some imfo no posting them... So I'll be checking with you both....posting this 424,repair sure to be a great thread! 

[Wheeler 2,275]

Ran 1/16” cable. I’ll solder the ends on for the attachments. 50’ cable was $18.99 at local store 

[Wheeler 2,275]

$76 for new bearings & seals. I’ll have them thur. 

[Wheeler 2,275]

These 424s are super simple to rebuild. 2 bearings, 2 seals & a cable all that can really go wrong… I man if u engage the 4x4 at wrong time, there is potential to strip shift gear. But I’ve never done it. I’m gonna install this one on bike, then rebuilt the other one as well!

[jeepwm69 6,561]

The cable is the hang up for most people.  If you can figure out a way to make a good replacement cable you'd have a line of people wanting them.

[Wheeler 2,275]

28 minutes ago, jeepwm69 said:

The cable is the hang up for most people.  If you can figure out a way to make a good replacement cable you'd have a line of people wanting them.

 

I’m on it rite now! Cable half done. Just doing some measuring, so I get it rite first time.

 

I should have taken a pic of the led I have on cable. The pic looks bad, but I can tell u, it surely will not let go. I used lead free solder which is stronger as well. 

 

 

Edited November 14, 2022 by Wheeler

[Wheeler 2,275]

Almost done. Then I’ll clean up this thread to make it more useful. 

[jeepwm69 6,561]

2 hours ago, Wheeler said:

Almost done. Then I’ll clean up this thread to make it more useful, and make Jeepwm69 a couple of cables to have on hand.

 

Fixed it for you.

[Wheeler 2,275]

1 hour ago, jeepwm69 said:

 

Fixed it for you.

Thx jeep pics & video added. But I tried twice to add text & never shows up. We can delete the other posts/pics I had if we can. I apologize as I’m terrible for not waiting untill I’m done 100% before posting up. 

[jeepwm69 6,561]

Looks awesome!  The lack of availability of the cables is the big problem now.  The bearings and seals are easy to find.

 

I knew cables could be made, but had no idea where to have it done.

 

Will you share specs and who made the cable, or offer replacements for sale?

[Wheeler 2,275]

Hey Jeep.. like I mentioned. I just made the cable myself. I used 1/16” galvanized cable off a 50’ roll. Then as per pics, soldered up the ends to fit inside the holes via lead fee solder which is wayy stronger then lead solder. 
 

IF ANYONE wants to send me their broke 424, yes I can spource parts & repair. 

[Wheeler 2,275]

Looks like I have my first customer I’m gonna help out. Have a 424 enroute to my place in Alberta from NC I believe. Gonna do full rebuild on it. 

[Fishfiles 16,948]

I seen your ad on the 300 Club , I think you will do good , I see a lot of broken cables over  there on that site ----------   seems there is always someone selling one with a broken cable and needing rebuild , maybe you can fix and flip them ------- wish I would have saved some of the broken cables I throw away 

[Wheeler 2,275]

3 hours ago, Fishfiles said:

I seen your ad on the 300 Club , I think you will do good , I see a lot of broken cables over  there on that site ----------   seems there is always someone selling one with a broken cable and needing rebuild , maybe you can fix and flip them ------- wish I would have saved some of the broken cables I throw away 

 

that’s the thing fish… the broken cables are garbage. I installed a new one. A lot easier than I thought. 

[_Wilson_™ 5,837]

Wheeler...... You have a customer right here, when / if mine goes.... I'll be sending it to you! I think this might be a great post for paying it forward. 

[jeepwm69 6,561]

I bought one used several years ago for $100, cable was good, but the actual driveshaft part was full of gunk and seized up. I replaced the bearings and seals and greased everything and put it back together.

 

If I recall correctly I bought the bearings and seals off of eBay and they were fairly cheap. The original bearings had part numbers stamped on them so it was easy to find replacements, and I used Koyo bearings.  
 

The cable has always been the elusive part

[Wheeler 2,275]

Another one done & should be getting shipped back to NC tomorrow. She was in really, really rough shape… like new now!

 

 

 

[_Wilson_™ 5,837]

Looks great wheeler! What kinda grease did you use  ? Cuz, it Looks kinda like mystic red.  JT-6 Hi temp number 2 grease.

[Wheeler 2,275]

@_Wilson_™ it’s Amsoil Synthetic. It’s label said the ur is for tie rods, balljoints, bearings, gears ect. So I figured it be good stuff. 

[shadetree 5,407]

do you have a source for cables ?, what about any parts for these ?. i used to know where a couple of these were, one for sure still on atv, pretty sure the cable is frozen. the other one was in pieces if my memory serves me correct ?. i think if i could round the parts one up, send it to you, let you rebuild it, pay you some rebuild cash, i could make a good profit from at least one of them. the full one just needs a cable, as i know very well, this is why warn stopped making them.

[jeepwm69 6,561]

The 300 ones are bringing $$$ now.  People are even buying them for other models to convert them to work with a 300.

 

 

[Wheeler 2,275]

8 hours ago, shadetree said:

do you have a source for cables ?, what about any parts for these ?. i used to know where a couple of these were, one for sure still on atv, pretty sure the cable is frozen. the other one was in pieces if my memory serves me correct ?. i think if i could round the parts one up, send it to you, let you rebuild it, pay you some rebuild cash, i could make a good profit from at least one of them. the full one just needs a cable, as i know very well, this is why warn stopped making them.

Hi shade. I make the cables. Bearings & seals I use Motion Canada (bearing shop). I use black rtv for the gasket. 
 

The one I just rebuilt had a seized adjuster, had to clean up bunch of rust & pitting, brake clean inside the cable housing, then oil, anti-size on all threads ect. Snap ring broke & had to buy a snap ring kit. It was in brutal shape, but like new when I shipped it out today. 

Edited December 3, 2022 by Wheeler

[retro 3,744]

Brazing rod and flux works great for attaching cable ends to new cable too. If the new cable is galvanized (or stainless steel) the brazing won't stick though. Gotta be clean uncoated steel wire/strands. Sanding the end of the new cable to rough up the surfaces insures the brazing will flow into the cable ends and bond them using less direct heat. Like sweat soldering... same technique, most of the heat from the torch flame should be directed into the cable end part, since the cable loses it's temper if it gets red hot.