Rebuildable Shock Absorber


First looks at a rebuildable shock. After disassembling it, I'm not convinced that it's a Willys original. The internal construction is a bit different than shown in the maintenance manuals, and it is not adjustable. It may be an earlier non-adjustable version.

This is quick 'n dirty, photos are not the best, but I wanted to get it up for comments.

The special spanner for taking it apart.

Homemade from mild steel plate.

The tabs are 1/4" wide

After a session on the plasma cutter to get a rough shape, it was fine tuned to fit w/files & die grinder.

Bottom eye of shock is mounted in a vise.

Liberal use of Kroil to break it loose from rust.

The "knockouts" (actually tabs, they don't come completely off) are bent back to expose the tool notches.
The special spanner in place.

A few back and forth rocking actions began to break it loose. Then it unscrewed easily.

Once the seal cap is unscrewed, the piston pulled out of the lower sleeve.
The lower tube w/sleeve still in place.

There was about 5 oz. of very dirty fluid still in there.

After dumping the oil, these are the parts that came out:
  • lower tube
  • lower valve
  • inner sleeve
  • upper tube w/rod & piston
The piston/valve assembly is still attached to the rod
All the piston/valve components are held to the bottom of the rod by a 5/8" nut.

Remove the nut, and the remainder of the piston/valve assembly comes off.

All the pieces spread out.

All the parts in the bottom row get assembled to the upper rod.

Closer views
Parts which go under the piston.

(piston at far right)

Parts that go above the piston.

(Main cap w/seal at far right)

The pressure sleeve is a simple rolled tube.

The weld seam has split open, so this piece is no good anymore.

The bottom valve just fits into the bottom of the sleeve. It's held in place once the sleeve is dropped into the lower tube, resting against the bottom of the tube.

The rubber seal and cupped washer provide the seal for the top cap. The rubber seal is like new. Soft and pliable w/no wear or deterioration after 60 years!

The head cap/rod guide.

This is the only item really in need of replacement.

Aside from being rusted, the rod seal looks questionable.

But, it did hold oil, and the shock still had good damping action!

More to come!