This weekend I finished rebuilding the reduction boxes. Luckily I was able to do this with engine/transmission still installed. It’s a relatively simple process overall, but because most of the parts involved are press fit I had to get creative and make/modify various pulling/holding tools. The old bearings didn’t have any signs of complete failure (yet) but most did have rust pitting and a few had a fair amount of excess play. Driving the bus after the swap is a night/day difference in noise. Its still loud, but now that a major noise source has been eliminated it’s just a matter of tracking down all the miscellaneous body air leaks and other minor noise sources.
Also, I finally found a passenger front lower seat section – these are hard to find since they’re specific to the ‘walk-through’ option, especially since I already had the top part and didn’t want to buy the whole thing. The one I found only included the springs without the seat frame itself, but the frame seems easy enough to fabricate and I’ve started on this using scrap metal from the incorrect (vanagon?) seats that came with the bus when I got it.