g-man
SILVER Star
Felt like Alice in wonderland today going down the rabbit hole. pulled the transmission and transfer case, removed the clutch and the flywheel and flywheel housing. Replaced the rear main seal. Tomorrow I will install the new clutch. The old one was 10 year old with 80k on it but really looked pretty good. The reason I pulled it was because of a clucking noise coming from the clutch when I pushed and released the pedal. Also wanted to replace the rear main seal. the grease was mostly gone from the two points of the clutch fork, ..one at the slave cylinder and the other on the ball just inside the flywheel housing. Slight wear inside the cupped shaped depressions. I'll grease it up and put it back. The ball had no wear ...have not checked the slave yet. At least I learned that all I need to do for that again is remove the inspection plate at the bottom and reach up in there.
I need to get some thread sealant for the flywheel bolts. Also I am building a crib out of 4x6" lumber to sit the transmission in ..so I can dis-assemble the transfer case. . so two pieces laid on the ground then the next two pieces 90 degrees to them laid on top of them at the corners or just in from that. maybe just run carriage bolts down in them to pin together. Leaving a space in the middle to accommodate the input shaft.
I had some questions about the operations that the fsm left rather vague.
1. Pulling the t-case shifter. basically in this step the fsm just says to remove the shifter with a picture of a wrench on a nut. I removed the first nut I came to under the floor. the bolt wouldn't budge And the shifter wasn't coming off. Back to the pic ...looks like he's wrenching on the second part of the shifter down further on the transmission where it bolts. I removed this nut and pulled the cotter pin out of the smaller leg that goes back to the transfer case. It came loose but no way is all this thing going back up through the floor. No problem just pulled it down and out..shift boot and all. Once removed I'm still wondering if the first joint is pressed together ?? The head of the bolt has to flats and other two sides curved like semi circles...I guess it's a sst thing? But no reason to remove it now. Right? It can all get shoved back up through the hole. See last pic of the shifter in the vice.
2. Not in the fsm but my flywheel surface had some small roundish to oval black marks and just black swirls mixed evenly with lighter color...burns? I feel no deformity when i rub my hand across the surface. My vehicle makes no shimmy upon release of the clutch.
I need to get some thread sealant for the flywheel bolts. Also I am building a crib out of 4x6" lumber to sit the transmission in ..so I can dis-assemble the transfer case. . so two pieces laid on the ground then the next two pieces 90 degrees to them laid on top of them at the corners or just in from that. maybe just run carriage bolts down in them to pin together. Leaving a space in the middle to accommodate the input shaft.
I had some questions about the operations that the fsm left rather vague.
1. Pulling the t-case shifter. basically in this step the fsm just says to remove the shifter with a picture of a wrench on a nut. I removed the first nut I came to under the floor. the bolt wouldn't budge And the shifter wasn't coming off. Back to the pic ...looks like he's wrenching on the second part of the shifter down further on the transmission where it bolts. I removed this nut and pulled the cotter pin out of the smaller leg that goes back to the transfer case. It came loose but no way is all this thing going back up through the floor. No problem just pulled it down and out..shift boot and all. Once removed I'm still wondering if the first joint is pressed together ?? The head of the bolt has to flats and other two sides curved like semi circles...I guess it's a sst thing? But no reason to remove it now. Right? It can all get shoved back up through the hole. See last pic of the shifter in the vice.
2. Not in the fsm but my flywheel surface had some small roundish to oval black marks and just black swirls mixed evenly with lighter color...burns? I feel no deformity when i rub my hand across the surface. My vehicle makes no shimmy upon release of the clutch.
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