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Very impressive detective work Ben! Mystery solved on possible difficulty with 2hi and 4hi shifting. T-case cleaning looks awesome! You're doing a very thorough job of sorting out all the issues.Still chugging away as parts and time roll in. Yesterday I split the trans and t-case in prep for cleaning and resealing. I loathe cleaning parts but the end result is worth the effort. View attachment 3007321
T-case as removed for comparison.
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When we drove the cruiser at time of purchase, it was having a fuel supply problem so getting through the gears was challenging. We got through all 4 and reverse with no noises or vibrations so I had a feeling if there were issues they must not be terrible. Also tested out 4wd and had a very hard time shifting each way between 2hi and 4hi. T-case coming apart was in my mind from the beginning at that point.
When prepping to get the drivetrain out of the cruiser, I noticed the rear output housing had the bolts barely finger tight and the long bolt was about half a turn in; well something must be up. Removing the front driveline presented the potential reason this cruiser was taken off the road, or at minimum, why the output housing was loose. The front drive flange had a lot of side to side play, likely bad bearing. Upon tearing it down, I found the cage bearing on the rear of the front output shaft scattered throughout the front nosecone! That little bearing with the small rollers let go at some point. Luckily, all the pieces were contained in that shifting area and I didn’t find any shrapnel in the rest of the case. New bearings on the way. View attachment 3007322
Good idea on pilot bearing. I see we also have a new thermostat. I glad your assistant noticed the missing parts!Engine is in, but my assistant thinks something is missing….View attachment 3009159View attachment 3009160
Pre-install. Checking pilot bearing fit after polishing input shaft. Don’t want the reverse problem I had on disassembly. View attachment 3009165
Nice work so far. But why an after market muffler? The factory muffler is still available or at least is was when I redid mine not too long ago.Thermostat housing is the original. Sandblasted and wire wheeled to look new.
Today was start of exhaust. Ran out of gas for the tig but just about done. Stainless with a walker quietflow. View attachment 3009657View attachment 3009658
Ben that stainless exhaust looks sweet!Thermostat housing is the original. Sandblasted and wire wheeled to look new.
Today was start of exhaust. Ran out of gas for the tig but just about done. Stainless with a walker quietflow. View attachment 3009657View attachment 3009658
The exhaust was very rusted out so it was all being replaced. Tom wanted stainless so he never needed to deal with the exhaust again.Nice work so far. But why an after market muffler? The factory muffler is still available or at least is was when I redid mine not too long ago.
Stainless makes sense for longevity and that muffler is tucked up higher than the stock one too.The exhaust was very rusted out so it was all being replaced. Tom wanted stainless so he never needed to deal with the exhaust again.
Meant temp thermocouple sending unitGood idea on pilot bearing. I see we also have a new thermostat. I glad your assistant noticed the missing parts!
New gas tank looks nice tucked up in there.!Ben that stainless exhaust looks sweet!
looking great Ben....emissions spaghetti looked like fun!Not many updates posted but lots of progress this week. Been running all the emissions spaghetti with new hoses. Manifolds and carb, as well as accessories are all on. Finished the exhaust. Ended up ditching the stock setup that leaves the manifold in 2 small pipes and just running 2.25” stainless direct from the manifold. Every stud broke on the exhaust so I had to cut, drill, tap and replace the 3 to exhaust flange and the 2 for the egr pipe, as well as the outer 2 that go into intake. Cleaned, inspected and resealed the transmission. That needle bearing for the front output of the T-case showed up today so I was able to finish the rebuild on that, set the proper preload on the bearings with a shim assortment I had and get the trans and t-case joined back together. Most of the pics I took were to show myself how things go back together so not so interesting.
But here’s the remainder of the bearing I cut out next to the new one. View attachment 3015282
Tom got the new BFG’s mounted up.
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Trans and T-case rejoined in blissful matrimony.
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Vacuum hose spaghetti.
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Cityracer front and rear mats in place and relaxing into position. View attachment 3016881View attachment 3016882
New spare mounted and cleaned up a crusty stock hubcap I had laying around.
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With any luck, tomorrow will be the fire up day.