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I remember when I pulled mine, I had this fear of being stuck under the truck and trying to get it clear of the dowel pins and not getting it teeth side down in my forehead. I chose to lay out some thick carpet under the truck and tap it off with a rubber hammer.

I have the same fears but I'm going to put the jack under it before I try to take it off the pins..

My problem right now is failed in getting the pilot bearing out and wondered if I can remove it after I get the flywheel on the ground..

Never easy is it.

Doug

Got the slide hammer in today and set it up. Hit it about 50 times before I was wore out. Sprayed it with blaster and took a break.

Came back and sprayed it again then using a long socket and my big ball peen hammer hit it a half dozen times.

Broke out the 3/4 nf tap that also came in today and got that started. Took about 10 minutes or so and got the bearing broken loose and out.

To say I was relieved is an understatement.

Cleaned up the area and moving on to the flywheel. Got 2 of the 6 bolts loose and soaked the others with blaster and will give another go after a break.

Doug

Got the last bolt out last night. Thanks to Hotrod for the suggestion to use a wood dowel in the pilot bearing hole for the flywheel when it came loose. Took five minutes with a rubber mallet to ease it off and let it sit overnight because I was tired and didn’t want any mistakes.

This morning I moved the jack under the flywheel and lifted it a bit and took the dowel out. Lowered it to the ground and let it fall on the cardboard I had there.

So it’s off to the machine shop this afternoon.

Have other tasks to get back to while waiting on it to get done. Need to remove the sending unit and replace it with one I tested to be sure it worked. I didn’t have a VOM when I put the first one in. Hope this solves the gas gauge not working problem.

Also found the source of the break fluid leak. Will do that next.

Doug

Picked up the flywheel this morning and it looks good.
Now I need to do other things in the area before I can start reinstalling the drivetrain.

Need to change out the fittings on the brake master cylinder while the area is clear and remove some of the crusted dirt layered on the frame around the trans.

Also need to install a line bracket for the brake line that runs along the frame below the transmission while it is easy to get to.

Doug

I did a check on the speedometer. Had hooked up the drill to the end from the transmission and the speedometer didn’t work. Then a bolter suggested running it in reverse and it worked just fine. That got me to remove the speedometer fitting off the transmission and clean it up.

First thing is that it is all metal. They knew how to make things that lasted back then.

Second thing I noticed was it had a tooth missing. I wonder where that went.

I don’t see an obvious way to take it apart so asking for help again.

Can the whole fitting be ordered?


Doug

Doug,

You may be able to locate a replacement, but need to know some more details to try and help identify the correct original part number for your speedo drive gear.

Needed:

Number of teeth on the driven gear (the piece you have pictured)

Number of teeth on the drive gear (affixed to the transmission output shaft).

You should be able to shine a flashlight in through the hole and get a count of the drive gears teeth without having to tear the transmission down.

Come back and let us know what you have and we can try and help find replacement.

Dan

The speedo gear has 13 teeth.
The transmission gear has 5 teath.

Doug

You really should put the tranny in neutral, jack up at least one rear wheel and have someone turn the wheel by hand slowly while you watch the teeth go by inside the hole on the tranny. If you see any damaged teeth in there, replacing just the driven gear might not fix the problem.

The tranny is sitting on the floor so thats easy to do.. which I already did
There are partially broken teeth on the tranny gear...
I'm worried where the pieces went.. going to flush the tranny after I get it cleaned up and see if I can wash out some pieces..

Doug

Partially broken teeth on the tranny gear really means that gear should be replaced. Mating a replacement speedo gear with a damaged transmission gear will damage the the speedo gear in short order.

Problem is finding one or both. May just not have a working speedometer

Doug

When looking for the gears check with Novak. They do a lot of SM-420 work, mostly modifying them to fit in older Jeeps which like the SM-420's first gear ratio for rock climbing.

No luck on the speedo gear but did get the flywheel installed last night... now to get the pilot bearing in. Hopefully this afternoon..

Doug

After three tries I got the pilot bearing in straight and down.

Now waiting on a response about torque values for the flywheel and pressure plate.

Doug

Doug,

See this 235 Torque Specs older post reply for torque values for your flywheel and pressure plate.

Dan

I haven't followed/read this entire thread carefully. (I apologize)

However, here are some torque specs that might be helpful.

Feel free to delete this post if it is redundant and/or not useful.

Unfortunately, that only covers assembling the pressure plate to the clutch cover assembly, and not the cover to flywheel bolts. Not even on the next page.

Got the clutch and pressure plate installed.
Then put in the clutch fork and throw out bearing in place.
Now have to figure out how to get the trans on the floor jack to get it up and in place.

Doug

If you have an engine lift, you can lift the tranny up tru the removed transmission floor cover, using rope. Easy peasy!

Don't forget to install headless guide bolts to help align the transmission as you are guiding the input shaft through the clutch into the pilot bearing.

I’ve got them on the workbench to grind on tomorrow.
Today I got the trans back under the truck and will get it set up to lift it by Tuesday.

Slowly getting there.
Doug

Doug,

Another minor but important reminder on fabricated guide pins.

Grind/cut a flat tip screwdriver slot in the ends so you can easily remove them after the transmissions is set.

I learned that here in Stovebolt!

Dan

I made sure they were long enough that I can put a wrench on them if needed.

I think your picture shows the pins installed screwed into the tranny and sticking into the bell housing. You may have big trouble getting the tranny all the way in if those guide pins hit the clutch, let alone getting them out after the tranny is in place. Screw them into the bell housing (top bolt holes) and slide the tranny over them. That way there's lots of room for getting them out after the tranny is slid home.

We’ll find out if this works shortly. A bit of southern engineering.

Doug

Doug,

Just a note that I agree 100% with Kevin!

Both guide pins need to be in the top bellhousing holes only.

That pin threaded into the transmission lower mount location is way too long to allow for full forward setting of the transmission AND still be able to extract it (must pull out from the front).

Dan

It looks like your lifting mechanism is going to fall short of getting the transmission up to the required location unless I am not understanding your process.

It is unfortunate tha tyou do not have a cherry picker/engine lift. They can be used for so many things.

That and your system looks very top-heavy and unstable. Please be careful with that, as you don't want to injure either yourself or the transmission. You'd be better off renting a transmission jack.

No sir, you are going to struggle with that. Both bolts at the top of the bell housing. Slots on the end. I learned that tranny trick here and used it
by myself many times.

Build a base made of wood for the tranny to sit on your floor jack. Low as possible.

Fill in with smaller pieces of wood. Ratchet strap that thing on there. Once you get it on those top bolts ,it'll slide right in. Bolt up the bottom 2.
My top bolts, I could hand loosen after that. But slots cut in the end might help.

Ended up biting the bullet and bought an engine hoist. It was still tricky because it was at the end of its reach to lift the trans. The guide bolts worked like a charm. They were easy to remove after I got two bolts on and tightened.

So transmission is in. Now on to the u-joint and cup.

Doug

You will find a lot of uses for that engine hoist. Mine sits out of the way most of the time but when I need to lift something it really comes in handy.

That’s what I figured too. Should have never sold my last one. Lol

Now I have a new problem. The clutch doesn’t work. It stays engaged. I’ve adjusted it out as far as it will go and it still doesn’t disengage.

Now what.

I’m going to put a thread up in drive train also

Doug

Ok. Pulled the trans and clutch and compared the new to old one.

It won’t post pictures atm. I’ll follow up with some later


Doug

It’s obvious now that I take the time to look at them. New clutch has a different profile altogether.

Good news is O’Riellys gave me a refund when I brought it back.

Ordered one from the Napa store that will be here Monday.

Fingers crossed

Doug

Ordered a clutch kit from carparts.com. It looks like mine and I’ll find out tomorrow if it fits.

If that fails I found a clutch rebuild place in Kentucky that will be my next try. They say they can do a same day turnaround.

Another day of waiting for parts.

Doug

I seem to recall seeing that you received your rebuilt clutch but have not seen any further updates. Just curious how it all came together. You have had more than your share of problems that I suspect were unforeseen.

Got the rebuilt clutch back. Looks great.
Just finished installing it. I had forgotten to order a throw out bearing with it so had to wait for it to come in today. So hopefully tomorrow I’ll get the clutch torqued down and get the tranny back in.

Have out of town company coming in shortly so had to pause things.

Will update asi get things done.

Doug

Got the clutch torqued down and started working on the trans installation.

Almost got it but discovered I put the throw out bearing in backwards of all things. In the process the clutch arm came loose. Had to move the trans down and out of the way. Will give it another go in the morning.

Doug