Started pulling the front axle apart. There was good grease in both front bearings. After the way the rear axle looked inside I was not expecting the front bearings to be worth anything. They cleaned up super nice with no wear marks or any visible defects. The rotors are shot and way below minimum thickness. I already got new ones ready to go on.
Once the coolant system passed its test. I went ahead and put the Banks air filter box on and all the plumbing that goes with it. The CDR valve plumbing required some creative thinking and an old front breather to CDR hose to donate about half its length at a certain curve to make everything connect. It looks good and with a CUCV mount for the CDR. Should work properly.
I already mentioned how the transfer case to bellhousing support rod had to grow 2 inches. Yet, the transmission crossmember had to go back 1.5 inches. The transfer case shifter rod had to gain 1.25 inches. I can only guess it is all a result of a longer transmission, aluminum t-case mount and swapping over to a 241 from a 208.
I also figured out that a GMT400 4L80E shifter bracket on the side of the transmission is different than what the TH400 in a square body has. The pivot center of the shift arm anchored in the frame is different. It moves in a different arc that will hit the floor. I need to get one off a 400 at home and swap it in. Once that is done then I can make a new mount for the frame end. We already added 3 inches to the shift rod which attaches to the column up by the master cylinder. Since that is adjustable, I just put extra on so we wouldn't end up 1/8" too short or something screwy like that.
I think all the wiring is done but can't test it. When I had the valence/radiator/cooling stack off last week to fix the water pump leak. I had to remove all my battery cables. I put them back on routed to make sense with the batteries on their mounts instead of hanging down by the front tires so I could do test with the batteries on foot stools.
The fenders, inner fenders and battery mounts are all ready to go on. It is just so nice working on the front axle with out the body in the way though. Once the front end is done, brakes are bled and transmission cooler lines are run. The rest of the body will get put on.
Next week is spring break for us so I should finish making the hood, grill, grill surround trim, head light surrounds, front bumper and grill guard all the proper shade of green at home. Maybe.