Service Brake Cross Shaft Rebuild

[JRShaw]

I have just picked up my service brake cross shaft today from a friend's machine shop. He helped me by pressing out the lever arm pins, as drilling them out was not successful. The shaft section under the spherical bearing portion is noticeably worn. I believe that I read some where that the diameter of that shaft portion was supposed to be 13/16" (.8125"). QUESTION: Is there anyone known to you gentlemen who you would recommend that has the proven skill set to build the two shaft portions back up as well as turn them down to size?? Thank You in Advance!

[Dick M]

Another option is to use split bushings available from suppliers on a worn shaft. Very easy to install and work perfectly.. I have had them on my A for 15 years without incident.

[Rip]

I have purchased split bushings and have a question. Does one Dremel/cut off the old bushing? Would rather not remove the lever arm. Thanks, Rip

[BRENT in 10-uh-C]

Please don't use split bushings. They are a band-aid at best.

Instead, just weld up the worn areas and re-machine them back to size. I/we do not worry with remembering the size. Just chuck the end that the arm was slid/pressed over into your lathe exposing .050"+/- of that unworn area to be used as your finished size guide. Then just machine the welded area until it is round.

If by chance you have one or two small voids where the welding did not completely fill it, it is no big deal. Also, you will likely need to make a cup to slide over the opposite end with a 60 degree centering hole so you can use a live center. Remember that the cross shaft was bent after it was machined, so you really cannot use the original centering hole.

[Bob C]

The links show a couple of options for worn shaft. https://www.brattons.com/service-bra...-bushings.html

http://www.snydersantiqueauto.com/re...ke-cross-shaft

Bob

[wrndln]

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I do what Brent does, except he has a metal lathe. I don't have a metal lathe, so I dress down the welds with a Dremmel tool and file. I can get the built up shaft pretty close to round. The brake shaft doesn't turn very much, so I doesn't have to be perfectly round, like a lathe would do. I wish I had a metal lathe, but I don't have the space for one or the skill to operate it. Both service brake shafts I have rebuilt with new woven bushing work just fine - no play and turn just fine. It is some work to remove the end brackets/worn bushings, weld up the shaft and dress the welds down, but that is definitely the best way verses a band-aid like using the split bushings.
Rusty Nelson

[briphaeton]

I turned one side down that needed it and pressed on a sleeve. Worked good for me.

[ian Simpson]

Originally Posted by Rip

I have purchased split bushings and have a question. Does one Dremel/cut off the old bushing? Would rather not remove the lever arm. Thanks, Rip

That's what I did some years ago.

As the cross shaft hardly moves, the use of split bearings should not be an issue unless the shaft is very worn. I lucked out, mine was hardly worn.

Anyone bother to fit grease nipples (sorry I do not like the word "zerk")?

[txkhog]

I have used the split bushings and TIG welded them on. then just filed the high spots of the weld. Cannot tell the repair was done and structurally sound

GDG

[5window]

Originally Posted by ian Simpson

That's what I did some years ago.

As the cross shaft hardly moves, the use of split bearings should not be an issue unless the shaft is very worn. I lucked out, mine was hardly worn.

Anyone bother to fit grease nipples (sorry I do not like the word "zerk")?

You might not like the word "ZerK" but that is the proper term. Oscar U. Zerk, born in Austria, was living in the USA and working for the Alamite Corp. in the 1920's when he invented, and patented, his "lubrication receiving nipple" (US patent 1,619,454) .

[Big hammer]

I am with Ian, I like nipples also, no you dirty old guys, grease nipples :-)