Steel Soldiers::Military Vehicles Supersite - View Single Post

steelsoldiers · 10-11-2009, 13:59

I spent a day working on the 925A2 yesterday. It only rained on me twice, so that was good. My primary focus was closing up open air lines and working on the electrical system.

I installed the front service and emergency gladhands. Then, I reconnected a flex line at the primary air tank. I also installed 2 low-air sensors on the primary and secondary tanks. Once I got those installed, I started the truck to look for more leaks. I found one at the wet tank where a fitting had been removed. There were 2 small lines hanging loose there. One went to the air dryer and I believe the other went to the brake relay valve. I didn't have a t-fitting or the required adapters to hook them up, so I used a pipe plug so I could move on down the line.

The air tank drains started blowing next so I was making progress. I shut them off and then there was a hose leaking under the dash. That supplied the air to the CTIS and required a in-line air dryer to be installed. Luckily, I knew it was missing so I had already ordered one and brought it with me. Then, the pressure gauges started climbing. Once they reached 90 pounds (I think) the secondary system kicked in and I had air leaking out of a wiper switch under the dash. Just for giggles I hit the brake treadle pedal and "woosh" the whole system dumped and wouldn't hold air anymore.. WTF?

I shut the truck of to listen for a leak, but it leaked down so quickly I didn't have a chance to find it. I started the truck again, but it still wouldn't build up any pressure. I climbed underneath it and discovered a 3/4" air line on the driver's frame rail was cut and leaking. I traced it back along the frame and found that it was the vent line from the rear relay valve. It is supposed to terminate in the air intake stack. It shouldn't have air coming out except when you let off of the brake pedal so that means the relay valve is stuck open. I either need a new valve or it has something to do with that other airline that needs connected at the wet tank. Hmmm...

Both of the front brake chambers were disconnected when I got the truck so I figured they were shot. I took them off yesterday and they were both full of rusty water. Dang. Too bad because they looked brand spankin new.

Taking a break (pun intended) from the air lines, I installed a turn signal switch and a headlight switch. I flipped the service lights on and the one lonely side marker light on the whole truck lit up. I may have other issues though because the dash lights came on only after turning on the black out lights. Hmmm... again.

I also installed a new clamp on the turbo down-pipe. Thanks Will. I need to put a muffler on it because the bottom is rusted out of the current one and it shoots diesel smoke down at the ground, which makes it tough to work under the truck with the engine on!

I also tested the tranny out. With the engine running I shifted through the gears and it would lurch a little when going from N into R or 1st so I at least have some sort of power transmission to the drivetrain.

I topped off the day by jacking the front end off the ground and filling the power steering system up completely. It took a bit to get all of the air out, but it was working smoothly when I was done.

All in all, it was a successful day. I am looking forward to getting the brakes in order so I can actually take it for a ride around John's farm.