So what did you do with your truck today?

[Jesus Freak]

You may not do it right the fourth time but you’ll definitely do it faster

That's part of it, AND you become an authority to tell everyone else how to do it with your long story of doing it 4x.

 

[DrCharles]

I guess this makes three times... I rebuilt it a few years ago (bearings and seals, complete disassembly); the second time was the last few days where I screwed up royally; and now this is the third time!

I did the autopsy just now... the new oil pump had actually welded itself to the mainshaft, screwing up the journals and even fracturing the pump castings! (see pics below). It only took 1.5 miles of driving below 30 mph to do this... Not sure why this happened unless my oil pump arm mod was a hair too long and pushed the pump case against the shaft - or possibly I didn't get the pump centered properly although it felt correct at assembly and turned smoothly.

So now I need another new oil pump and arm, plus either a weld and remachine of two shaft journals plus boring/sleeving the inside of the chain drive gear, or just replace the mainshaft and the gear.
I just bought a complete assembly on ebay (oil pump, gear and shaft). Hope it's good, the pics on the listing looked ok.

The carnage:

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This is after I carefully ground off the welded material (hoping it would flake off). No such luck!

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More to come

 

[ttman4]

Well today I parked "Bessie" about 50' away & let her watch me work on my 40'x64' shop!!!!

 

[1mouse3]

Old girl no longer has a questionable mount.

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[Dirtleg]

I think you pick the wrong person out the line up. This one is closer, but still not the same.

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I dont think this one is it ether.

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Pic 1 lift is at awkward angle and bed collapsed.

Pic 2 big as steel plate and lift is a hero.

Good recovery.

 

[1mouse3]

Pic 1 lift is at awkward angle and bed collapsed.

Pic 2 big as steel plate and lift is a hero.

Good recovery.

Thanks and good catch, you cant find the weak point without trying. Still need to find a tackle block rated for at least 750lb, so the cable dose not drag on a shap edge.

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I put added support on the underside as well.

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[Austin86250]

Had to grab another parts truck, was my first tow with the turbo and boy is it night and day I could never go back

 

[The_Josh_Bear]

Had to grab another parts truck, was my first tow with the turbo and boy is it night and day I could never go back

Heck yeah!! Turbo for the win!

 

[R Squared]

Took the truck on a 300 mile trip today picking up the new trans for the truck. Stole this ZF5-42 for $300, including the flywheel, flexplate, shifter, and even had a PTO bolted on the side.
I’m already looking into a pedal box for the clutch, and am gonna order the hydraulics side of the house here soon. Hopefully I can source a driveshaft from a CCLB truck that’ll work.

The C6 and US Gear under drive will be coming out and be listed once the swap is done to hopefully offset some cost.

 

[DrCharles]

The (used) mainshaft assembly came in the mail this morning. I was pleased to see it also had the oil pump and chain drive gear still in place (guess the seller didn't feel like wrestling that snap ring off!) and also came with the (plastic) 2/4 shift fork in good shape

I also welded a piece of 5/16 rod to the end of the pump arm again, but this time I made sure it wasn't interfering anywhere or any binding, especially when I trial-fit the rear case half.

I just finished putting it all together except for final torquing the case bolts to 30 ft-lb and filling the ATF. It feels normal when I turn the output shaft by hand, and this time I checked to see that the 4WD engages and disengages properly

It's been at least an hour so I think I will torque the bolts now, but wait until tomorrow before putting in the Mercon LV and dirt-road-testing. Crossing my fingers I did it all correctly... this time!

 

[IDIBRONCO]

Hopefully your truck will be driveable again tomorrow.

 

[hacked89]

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Bought another parts truck today

 

[Thomas87]

Was checking things out under the hood and noticed this... Oh boy

 

[IDIBRONCO]

Was checking things out under the hood and noticed this... Oh boy

Before you start worrying about replacing your radiator, check to see if the cap or even the overflow hose is leaking. I've seen both and they're both a cheap, simple fix. The leak may not be from either one, but it's sure worth checking out.

 

[Thomas87]

Bone dry around the cap and hoses while dripping steadily until it cools off. If I squeeze the upper rad hose I can see it bubble up from the seam in several spots