Project Little Green Turd

[wizkid00104]

Here is what I found.... Please point out anything I am missing....











Based upon what I can see here, I need a plastic shift pad on my range fork, I am replacing the mode fork since it is plastic and I have no idea how may miles are on it, and I am going to replace the front output bearing and seal. There was a lot of buildup around there and that was concerning to me.

I checked the mode operation manually and it locks in and the spring still works. One thing I did notice is that depending on how far you push the mode fork in, you can hear a scraping as if something is hitting case. I need to get the socket that fits that to get it apart. I don't have one quite that big.

Can anyone else provide more insight here? I'd like to put it back together and not need to disassemble it again

 

[wizkid00104]

I checked the lube in the front diff and could find any metal shavings. I am going to reassemble the t-case and test it further before pulling the front pumpkin.

 

[wizkid00104]

I pulled the front yoke out yesterday and I definitely need a front seal for the transfer case. I am going to pull the rear tonight and check it.

After talking to my buddies dad, he thought a u-joint in the axle shaft was causing my problem, but I thought about the noise it made and that just didn't seem to fit. A u-joint would not cause the front wheels to stop turning... I woke up at 4 am and realized it must be the splines on the front drive shaft that I chewed up! If I get time, I am going to inspect them this evening.

 

[1badexplorer]

Get this pile fixed yet?

 

[wizkid00104]

No. Didbt get to the drive shaft yet. Got the t-case disassembled. Front and rear seals are shot. Gonna replace those and outer bearings. Had to get Nikki's oil changed, cook dinner, and get a bunch of errands done. Going to the mountains Thursday night and Nikki works 12s, so accomplishing things is slow going. But you already knew that everything I do is slow


Sent from my iPhone

 

[wizkid00104]

Drive shaft splines were fine. Passenger side axle looked suspicious so I tool it apart. All splines are fine, but the axle looks as though it may have came out of the hub. My axle shafts never had the outer washers and clips, so I just let them be. Now I am going to add them.

Gonna repack front bearings and replace all the seals while I am at it. The old ones are toast.

Does anyone have mode hub for the BW1354 manual shift? I believe the 1350 uses the same part. I spotted some wear on mine and I'd like to replace it to ensure that wasn't causing my problem.

 

[wizkid00104]

I decided to chance the mode hub... and I am assuming the chain isn't stretched to badly...

I ordered a new mode fork, range fork inserts, front and rear output shaft main bearings, a seal kit, and some transgel assembly lube.

Started reassembly yesterday...

New front bearing and seal.




I am thinking that the shop that rebuilt this put gasket, then yoke, then washer, then nut on and cranked the hell out of it.

The correct order is yoke, then gasket, then washer, then nut.





Then rear seal and bearing. I added assembly lube to the speedo gear before installing it behind the seal.





Range Fork Pads






Then I reinstalled the rear shaft and yoke.





Then I realized that I need to take the front yoke back off to make reassembly possible. Put the front shaft in the case on the chain, then get the shifter forks lined up with the shifter arm on the case, and then get the oil pickup on the case, and then the magnet in the slot. I pushed the case together to test function. Once everything was good, I added some RTV all around the case and sealed the center section. Finally put the front yoke back on.







I did not skip on the assembly lube. It's an $8 tub that will probably last me for the rest of my life. The case turns nice and smooth. I am very happy with it thus far. I had to make dinner so I stopped there. Heading to Detroit for work, so hopefully I will get this finished up this weekend.

Nick, did you find any of those clips and spacers for the axle shafts?

 

[wizkid00104]

Transfer Case Reference Material

For anyone who needs it,

I ordered my 1354 Parts from Cobra Transmission and was very pleased with them. Parts are here: https://cobratransmission.com/index.php?main_page=index&cPath=3_2077

I used a reference manual from A & Reds Transmission. See here: http://www.areds.com/wp-content/uploads/Ford-Transfer-Case-CD-Web.pdf

I have had excellent service from Trans Parts Warehouse out of California too. See here: http://transpartswarehouse.com/

And finally, I found this really nice manual from 4x4brasil.com.br. See here: https://www.google.com/search?q=CAI...93&ie=UTF-8#q=CAIXA+DE+TRANSFERENCIA+B&W+1350

I converted them to images to paste here:

 

[wizkid00104]

T-case is assembled the rest of the way. With any luck I will get it re-installed tonight. I need to give the front axle a little attention. I am going to repack the bearings, replace the seals on the back of the rotors, and replace the seals on the axle shaft. 1bad has the spacers and clips for the outer axle shafts that my truck has been missing since I bought it. Hopefully the addition of those will solve any more problems as everything else checks out.

 

[merch]

thats good intel on the transfer parts!

 

[wizkid00104]

Thanks. It took a lot of research to find all that crap lol. I even had to learn Portuguese...

 

[wizkid00104]

Transfer case is completely re-installed. I also got the front passengers side axle back together. I am going to take care of the drivers side tomorrow.

I was a bit confused about the seals on the spindle. I got the correct repalcement part and then realized part of the old seal was still stuck in the spindle. I guess it was in need of replacement...

 

[wizkid00104]

Had a leak in the t-case. I didn't get rtv in an area where there is a hole on the lip of the t-case. Solved that with a bolt, 2 washers, a nut and a big ol glob of rtv. I am just glad I didn't need to disassemble it to fix it.

I put the passengers side of the axle back together. In dissembling the drives side, I found that the a spindle retainer nut striped. So after monkeying around with it for an hour or so, I finally go it off... From the looks of it, the nuts are softer than the knuckle studs. This is good for me because my problem should be solved with the correct size die to clean the threads back out.... hopefully that works.

 

[036speed]

Getting closer....
You are fixing or cleaning so many things, how are you going to know what the cause of the problem was LOL

 

[wizkid00104]

Getting closer....
You are fixing or cleaning so many things, how are you going to know what the cause of the problem was LOL

In the end I have a guess, but I am not certain. It started with the t-case and then I worked my way outward.... (it was based on the noise it made) As far as I can tell, the right axle shaft was pulled in so far that i wouldn't grip the hub. The problem is that I was looking for destroyed splines or something. Some proof that something broke and I just can't seem to find it... but I did notice that axle shaft was in a good 1/2" from where the out clip should hold it in place.

Picked up the repair parts for the knuckle at lunch today. Hopefully I'll have it on the road Sunday... Or I'll break something else.....

Oh, drivers floor pan now has a hole in it.... yay sheet metal work....