Posts Tagged ‘Safety’

Ball Joint Replacement – Jeep Cherokee Repair

Thursday, July 16th, 2009

How to replace the Ball Joints on a Jeep Cherokee

While I don’t fully understand the mechanism, our off road group has found a strong correlation between worn ball joints and broken front axle shafts. I did not really believe the theory until my ARB shaft broke. See the video of it breaking.

Shaft broken due to bad ball joints.

Shaft broken due to bad ball joints.

With the weight off the wheel you can see the joint separating.

Note gap in the ball joint

Note gap in the ball joint

I got my new ball joints from Crown Automotive. I installed the driver’s side ones last night.

Before I began, I coated my hands with Market America Clear Shield.

First, I lifted up the Jeep and removed the wheel.

Removing Jeep Cherokee wheel

Removing Jeep Cherokee wheel

Then, since this is an AMC Jeep, I used my 7mm hex bit to remove the brake calipers. Mopar Jeeps will use either a 12 or 13 mm socket.

Jeep Cherokee brake rotor

Jeep Cherokee brake rotor

using 7mm hex to remove caliper bolts

using 7mm hex to remove caliper bolts

Next I removed the brake pads and rotor hat.

brake caliper removed

brake caliper removed

storing the brake caliper

storing the brake caliper

brakes removed

brakes removed

I stored the brake caliper on top of the lower control arm and removed the pads and the rotor to expose the bearing.

Next I used a 13mm 12 point socket to remove the three bearing retainer bolts.

13 MM 12 point socket used to remove bearing bolts

13 MM 12 point socket used to remove bearing bolts

I carefully tapped the carrier out of the knuckle. I left the axle in the bearing since it will go right back in.

removing the bearing and axle shaft as a unit.

removing the bearing and axle shaft as a unit.

Next, I used a 3/4 inch wrench to remove the tie rod from the knuckle. This step is not absolutely, necessary but makes it easier.

Cherokee tie rod removal

Cherokee tie rod removal

tie rod removal tool

tie rod removal tool

Next I removed the retainer bolts from both ball joints.

ball joint nut

ball joint nut

I used my tie rod separator to separate the ball joints from the knuckle. It came off rather unexpectedly and hit the floor. Glad it missed my foot.

ball joint removal tool

ball joint removal tool

Next I used a wire brush to clean up the surfaces where the press would rest.

clean up

clean up

I collected the correct adapters to press out the upper joint.

ball joint press

ball joint press

The upper joint pressed out easily

upper ball joint removed

upper ball joint removed

Next I collected the correct adapters to press out the bottom joint. Note that the screw for the press had to pass through the upper ball joint hole.

lower ball joint press

lower ball joint press

The lower joint was very worn.

worn lower ball joint

worn lower ball joint

Then I collected the correct adapters to press in the new ball joints. Note that this is a newer Dana 30 and the surface for the press is slanted requiring a tapered adapter. Some of the older axles had this surface machined flat.

upper ball joint press in

upper ball joint press in

Pressing in the lower requires a tapered receiver cup on this axle.

lower ball joint press in

lower ball joint press in

With the new joints installed I began to put it all back together. There is not enough clearance for a grease fitting on the lower joint. The kit came with a fitting that I put in temporarily and grease the joint. I then replaced the plug.

ball joints installed

ball joints installed

I then installed the knuckle and tightened the bolts. I then inserted cotter keys to keep the nuts from turning.

ball joint nut and key

ball joint nut and key

I then replaced the tie rod and keyed it.

tie rod nut

tie rod nut

Next I greased the inside of the knuckle and reinstalled the bearing and axle shaft. I used the bolts to pull the carrier into place.

installing bearing jeep Cherokee

installing bearing jeep Cherokee

Next I reinstalled the brake rotor, pads and caliper.

caliper installed jeep Cherokee

caliper installed jeep Cherokee

With the wheel back on I am done and ready to do the other side. Well maybe later.

Wheel back on

Wheel back on

snap-on-ball-joint-master-press-set Snap On Ball Joint Master Press Set
US $247.50 (6 Bids)
Auction Ends: Saturday Sep-11-2010 10:00:57 PDT
  | Watch this Item
otc-ball-joint-press-model-7249 OTC Ball Joint Press - Model 7249
US $27.99 (2 Bids)
Auction Ends: Saturday Sep-11-2010 10:32:14 PDT
  | Watch this Item
new-3-in-1-ball-joint-u-joint-c-frame-press-service-kit NEW 3-IN-1 BALL JOINT U-JOINT C-FRAME PRESS SERVICE KIT
US $29.90
Auction Ends: Saturday Sep-11-2010 11:02:21 PDT
  | Watch this Item
new-3-in-1-ball-joint-u-joint-c-frame-press-service-kit NEW 3-in-1 Ball Joint/U-Joint/C-Frame Press Service Kit
US $34.95
Auction Ends: Saturday Sep-11-2010 13:11:08 PDT
  | Watch this Item
otc-ball-joint-c-frame-press-new OTC Ball Joint C-Frame Press NEW
US $108.99
Auction Ends: Saturday Sep-11-2010 17:21:23 PDT
  | Watch this Item
3-in-1-ball-joint-u-joint-c​-frame-press-service-kit 3-in-1 Ball Joint/U-Joint/C​-Frame Press Service Kit
US $38.95
Auction Ends: Saturday Sep-11-2010 18:27:15 PDT
  | Watch this Item
new-3-in-1-ball-joint-u-joint-c-frame-press-service-kit NEW 3-IN-1 BALL JOINT U-JOINT C-FRAME PRESS SERVICE KIT
US $29.90
Auction Ends: Saturday Sep-11-2010 19:04:12 PDT
  | Watch this Item
astro-pneumatic-ball-joint-press-&-4-wheel-tool-kit Astro Pneumatic Ball Joint Press & 4 Wheel Tool kit
US $68.95
Auction Ends: Sunday Sep-12-2010 3:35:26 PDT
  | Watch this Item
new-3-in-1-ball-joint-u-joint-c-frame-press-service-kit NEW 3-IN-1 BALL JOINT U-JOINT C-FRAME PRESS SERVICE KIT
US $29.90
Auction Ends: Sunday Sep-12-2010 11:03:08 PDT
  | Watch this Item
new-3-in-1-ball-joint-u-joint-c-frame-press-service-kit NEW 3-IN-1 BALL JOINT U-JOINT C-FRAME PRESS SERVICE KIT
US $26.90 (0 Bid)
Auction Ends: Sunday Sep-12-2010 17:22:48 PDT
  | Watch this Item

Workplace safety and acceptance.

Tuesday, March 31st, 2009

How to Improve the Safety of your Workplace

Acceptance

Knowing where you really stand is the first step to improving the safety of your workplace. All too often, I have seen managers respond to a directive to improve their plant safety by trying to cover up accidents. See my article on How to Improve your Safety Metrics without Improving Plant Safety for examples.

In order to fully understand how to make your plant safer, you need to accurately assess where you currently are in terms of safety compliance. Where are your trouble areas? How well do your policies and procedures reflect current practice? What is the emotional environment of the workplace?

If we fail to accurately assess the current situation, our measurements of improvement will be skewed. Sweeping problems under the rug will not help in finding effective solutions to them.

When beginning a new safety awareness program, we often see a spike in recordable injuries and illnesses. Sometimes this is due to employees learning what to report. Sometimes it is due to improved record keeping. But more often it is due to the safety programs being focused on accidents and injuries. The Law of Attraction teaches us that whatever we focus our attention on, we will get more of. New safety programs often demonstrate this law all too well.

Many managers seem to be afraid to accurately assess their actual workplace safety for fear of having their plant shut down by OSHA. If their plants are really that unsafe, then perhaps the reality of the situation is that the operation would be better off shut down and replaced with a safer one.

Allocating the time and resources to accurately assess a workplace environment requires a high level of commitment. However, you will not be able to effectively improve the work place safety until you accept the reality of the current situation.

Perhaps the reality of your situation is that you already have a very safe plant. Improvements may be hard to make. Compare your self to other operations in similar industries to see how you are actually doing. However, I find the only real and meaningful safety goal is zero accidents and injuries.

If you do find that you are truly the best in your industry as far as safety goes, then please make and effort to share your knowledge with others. Once you can accept where you really are in terms of work place safety, then you will know in what areas to focus your energy for the most effective improvements.

Begin by looking at your OSHA logs. Do they accurately reflect what is going on in the workplace? Or are injuries going unreported? Or do they show only frivolous results while the real problem goes unreported?

What about your safety policies? Do they really tell people how to do their jobs safely? Or do they simply list things they can do to get hurt? Remember that whatever you write down or focus on will expand in the thoughts and minds of the employees. Focusing on teaching them how to do their jobs safely will be much more effective than telling them not to get hurt.

How well do your work instructions reflect current practice? I will never forget a comment I heard during an audit review; “I did not know that was a procedure we were supposed to follow; I thought it was one we wrote just to satisfy [our customer]!”

By allocating the resources to audit your procedures and accepting the results, you will soon know where to focus your energies to create a safer work environment. Too many times I have seen audit reviews treated as punishment rather than a learning exercise. Management often fails to accept the poor results and rather than work to improve, they try to cover up the situation or become defensive.

Accepting bad news may be hard on the ego, but it is a necessary step in improving the process. Only by accurately knowing where you are starting from can you measure your improvement.

If you need help in making a true an accurate assessment of your workplace, you may need to bring in an outside auditor. Just be sure you are committed to accepting the results of the audit. OSHA tends to take a strong stance against employers who fail to correct situations that they have been made aware of.

If you would like me to help you assess your current situation and offer suggestions on how to improve, just contact me by email. Or you can read my other articles to know just what I would be looking for if I visited your facility. I am also available on a very limited basis for phone consultations. Email me for details. Just be prepared to accept the results before you ask for my help.

For more information on applying the principle of acceptance to personal development see these articles:http://www.stevepavlina.com/blog/2005/06/self-discipline-acceptance/
or

http://mikestrawbridge.com/blog/2009/03/acceptance/

Safety Glasses

Friday, March 13th, 2009

Safety Glasses

I have always hated wearing Safety Glasses. They are always in the way, they get dirty and I simply can’t see well through them.

However, I do like having my Safety Glasses on when I am doing work that generates debris like when I am running a table saw, or a drill. I can work much faster when I am wearing my Safety Glasses while performing these tasks.

I also love having my Safety Glasses on when I am working under a dirty Jeep. A pair of well fitted, lightweight fashionable safety glasses makes going under the Jeep much more fun and productive.

One safety policy I have always opposed is the blanket Safety Glasses policy. Usually this policy is put into place by people who wear prescription glasses and they don’t see why anyone would be opposed to wearing glasses all the time. They are used to it.

My first thought when I walk into a facility that requires Safety Glasses every where is, “Why do they have so many unprotected hazards that they need Safety Glasses everywhere?”

I always prefer to address hazards at their source. PPE should be the last line of defense against hazards. Especially when it comes to eye protection.

Eyes are easily damaged and you really don’t want to take chances with them. However, by making a blanket policy that you must have Safety Glasses on every where, you dilute the message that there are some places where extra care is needed to protect the eyes.

Whenever possible, guards and shields need to be designed to protect workers form flying debris that might damage the eyes. Also, work instructions and procedures can be modified to reduce the exposure to potential eye damaging projectiles.

For those situations where eye protection increases productivity, safety glasses can be required. Whenever safety glasses are required, there needs to be plenty of conveniently placed glasses cleaning stations. The provided Safety Glasses also need to be both fashionable and comfortable to wear.

When workers see the importance of wearing Safety Glasses and they see how they can feel more comfortable and confident doing their jobs, you won’t have to resort to forcing people to wear safety glasses. People will want to wear their Safety Glasses because it helps them do their jobs.

For more safety related ideas, see: http://www.mikestrawbridge.com/workplace-safety-training.shtml