The weather got nicer for a few days, so I got on the ground and put in fresh oil. I checked the transfer case, it was low so I changed the fluid. I got an economy squeeze bulb and spent probably an hour moving 2 ½ quarts. The shifter gasket was in bad shape on the 5LM60, I found a gasket for an NV3500 and swapped that out. I’m not completely satisfied as the gasket is thick rubber and the top cover shifts slightly as I move the shifter. The bolts need to be tightened down more to minimize this movement, but they are steel bolts going into an aluminum housing. When I got the donor truck the shifter was really loose. I found the top bolts were loose and two of them the threads were stripped. I put in helicoils for those two, helicoils into the top of an aluminum transmission case. I don’t like the movement in the top cover, I may put the original gasket back in as it is thinner and has a metal plate. I also attached the inner fenders. On to the interior wiring harness. I cut off the bulkhead connector, labeling each wire. Next I cut off the convenience center, then I cut the buzzer module and the relay sockets from the convenience center. I laid out the remaining harness, cut off the electrical tape, and started grouping and bundling wires. I sorted out the wires from the convenience center that I wont use, I could wrap these up out of the way, or I may remove them. With the harness loose I was able to reshape it to some degree. I’ll need a way to mount the fuse panel, so I made a box. The buzzer and relays will fit below the fuse panel. I’m also getting everything under the dash ready. I decided to go over the heater before putting it back in.
