Subways DT360 into my 94 F350

Discussion in 'Diesel Conversion Forum' started by subway, Nov 30, 2015.

  1. subway

    subway be nice to the admin :D

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    Small update, I got my new clutch and flywheel turned. I have to say, the guys at TruckPro in Harrisburg PA have been great answering all my questions and looking up parts. They would take the time to look up anything I asked them even if it was not for a sale and gave very comparative pricing.

    They even looked up my rear yoke saying it should be able to be removed from my spicer and bolted to my eaton fuller even though it could have cost them the sale of a yoke. They also double checked to make sure my clutch should work and fit the flywheel for me.

    If the weather holds tomorrow I hope to make some good progress getting this beast in. The instructions should help giving some great details on exactly the clutch position and how much it should move. That was a guessing game the first time around.
    [​IMG]

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  2. subway

    subway be nice to the admin :D

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    More good progress today. I pulled the rear yoke off the eaton fuller. It cam off fairly easily. The same could not be said of the spicer.

    It fought me but once it broke loose it was not to bad. It was a real hallelujah moment when the spicer yoke fit right on the eaton! With some blue loktite I torqued it up to about 350 to 400 lbs. 2 ft bar and a smidge over 200 me. One check mark down.[​IMG][​IMG][​IMG]

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  3. subway

    subway be nice to the admin :D

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    Next i took off the PTO and replaced the opening with a cover from the spicer. From what I can see it looks like all PTO openings are the same 6 bolt pattern. It fought me though. I can only fit a boxed end wrench on it and turn about a 1/4 turn at a time.

    I did notice the transfer case did have a PTO opening.....thing that make you go hhhmmmm.
    Some views of the transmissions side by side.[​IMG][​IMG][​IMG]

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  4. subway

    subway be nice to the admin :D

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    Unfortunately my hydraulic ram decided to take a crap on me so I had to take some time out and fix it. I had a spare ram that I was able to scavenge the small pump off of and I was back in business. I will have to get a new oring to fix the other one then.

    This is also what I saw with the mounts I made about a year ago. Even with 2 coats the paint is not really holding up.[​IMG][​IMG]

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  5. subway

    subway be nice to the admin :D

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    Next i bolted in my newly finished flywheel minus clutch and transmission to start the fitting. It was a lot of work wrestling that thing around under the truck. I ended up jacking up the truck and sliding it in on its side on a motorcycle jack. After it was under I could lift it up through the opening in my cab with the cherry picker.

    So far so good. I will have to re make the mounts but it fits. It hangs down a couple more inches and is about 1 1/2 inches wider per side but I didn't see any show stoppers. The shifter even comes through the same spot.

    I have to move the cross member back 4 inches so I ended the day with the pain in the rear task of re drilling all the holes in my frame.

    On a side note, I forgot to measure the travel of the slave cylinder before I tore it apart. I need to figure out the travel to set up the right amount of throw on the clutch. So if anyone can tell me travel of the slave cylinder when you fully push the clutch in i would appreciate it.
    [​IMG][​IMG]

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  6. F350camper

    F350camper BOOST!

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    Nice work man! I hear you on the rust through two coats. I almost wonder if its better to let the fabbed pieces rust, coat them with converter, then prime and paint. I keep touching undercarriage things up here and there with rustoleum, its hard to keep on top of it tho.
     
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  7. subway

    subway be nice to the admin :D

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    Yea I noticed some other areas under the cab are getting rough. I need to do something while it is still salvageable.

    Not much to show otherwise. This is where it slows down a lot. A lot of fitting, cutting and welding. I actually switched back to flux core. I could not seem to get consistent good welds with gas. I am sure it has to do with the metal I am working with. Even though I grind it down it still has small pits. That seemed to cause porous welds, not something I want.


    I had to grind out the welds and re do them. This ended up eating a lot of time. I am making progress though. I have 2 mounts about 75%. After that on to the clutch slave.[​IMG][​IMG]

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  8. subway

    subway be nice to the admin :D

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    Small update, I am getting stalled a little from a unexpected basement flooding.

    I did finish the transmission mounts so on to the clutch. I am going to have to flip the clutch shaft to the lower holes. You can see in the picture it will not clear the floor at all without a lot of sheet metal work I don't want to do. On the bright side this will place the slave cylinder back into a close to stock location instead of up side down like I had it before.

    I dropped the transmission back down and am going to try to put it together with the clutch in this time.

    I also drug my old transmission under and found the slave cylinder travel is 1/2 inch. Perfect, I just need to make the lever arm a simple 1:1 ratio to get the needed travel for the clutch now.

    More to come soon.[​IMG]

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  9. subway

    subway be nice to the admin :D

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    This clutch looks huge compared to a stock IDI clutch. I realised that the new clutch didn't come with an alignment tool so I came up with something. A 1 inch wooden dowel shaved down a hair fits the pilot bushing nice and tight. I then fit a PVC pipe over and ran some electrical tape around it until it fit snug in the clutch disk. Well if the women don't find you handsome they should at least find you handy![​IMG][​IMG][​IMG][​IMG]

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  10. laserjock

    laserjock Rebuilding! Supporting Member

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    I haven't seen red green in years. That made me laugh.
     
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  11. subway

    subway be nice to the admin :D

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    This thing is heavy so I put some studs in the top 2 holes to hold it up while it slid in place and I could put the bolts in. Once I tightened the bolts down with some loctite the wooden blocks dropped out behind the throw out bearing. This will set where the clutch arm has to be when I put it back together.

    Got the clutch in tonight before the rain moved in. [​IMG][​IMG][​IMG]

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  12. subway

    subway be nice to the admin :D

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    Got a good day of work in. With the pull clutch protruding out farther the transmission has to go back that much further before I can slide it in. To achieve this I ended up cutting out a section of floor. I cut it back just far enough to use the cherry picker to lift it in. Once I had that done it was fairly easy to slide in. My special MacGyver alignment tool worked!

    After that I got the cross member and mounts bolted back in so I could move onto the clutch slave cylinder. [​IMG][​IMG][​IMG]

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  13. subway

    subway be nice to the admin :D

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    A little set back with the clutch. I didn't notice it earlier but the bottom holes on the bellhousing are not drilled out and do not have the bushings pressed in to move the clutch arm like I had hoped. I can flip the clutch arm to face downward but still have to use the top holes. Unfortunately this is to high up and would put the slave cylinder right into the starter and mid engine mount.

    After some fiddling and searching I ended up ordering a Wilwood pull slave cylinder. I can't finish this out like I really wanted to today but I have other stuff to do.

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    Last edited: Jun 28, 2017
  14. subway

    subway be nice to the admin :D

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    I didn't get many pics since my phone died but I had to cut my drive shaft down about an inch. I didn't think I would have to at first since the transmissions measured almost the same overall but changing the rear yokes around threw that off.

    I got the drive shaft fixed and another item off the list. You can see the new transmission hangs a little lower but it is not bad. This is not an off road toy lol

    [​IMG]

    [​IMG]

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  15. subway

    subway be nice to the admin :D

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    I finished the day out cutting out a patch to fill in my cut out. I saved a clean section of bed from when I scrapped my old one. Using my cut out piece and some measuring I have a rough patch started. I will still need to bend it up to match the floor profile but I think it will work well. I am trying to do a push this week since I will be away next week and I want to have this together for some shake down time before the rally![​IMG][​IMG]

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