1999 Mounty 5.0 aka My Great Bad Idea

[410Fortune]

That is a nice bumper pull! Getting harder to find them in good shape like that

Now what usually happens is we decide to fix “one spot” in the floor and about 12 hours later the entire interior is gutted for a complete redo

 

[97Sandbox]

I'm officially in the midst of getting prepped to yank out the M5R2 for teardown. Last night I got the front seats and console out so I could pull the flooring back to remove the shift levers and trans tunnel cover. I also pulled the rear drive shaft and disconnected all the O2 sensors.

Tonight I got the exhaust off from the cats back, pulled the front drive shaft, front fuel tank bracket, clutch hydraulic line, and transmission wiring bulkhead. I got the downpipe disconnected from the header on the driver's side, but the passenger side is hanging on. Those bolts haven't even been on for a year and you already know I lathered them in high-temp anti-sieze lubricant. Hmmm. I sprayed some penetrant on and will get after it again tomorrow.

Once the exhaust is totally out of the way, the 4406 will be coming down and out and then it's time for the transmission.

Hey seasoned 4406 swappers: do you recommend putting new bearings and seals in the case while it's out? From what I can tell, my leak and bearing noise are both transmission related, but I noticed the 4406 rebuild kit is pretty affordable compared to the M5R2 kit. I'm realizing now I don't want to make a habit of pulling these things out haha.

 

[Turdle]

If you are concerned about it, rebuild while it's out.

The is a shim for the pump "notch" that wears out, you need to get that also.

 

[97Sandbox]

I haven't had any issues with it, but it's been bolted to this M5R2 it's whole life, so I assume it's been subject to the same neglect and/or abuse. I'll plan on evaluating the bearings when it's out and check the input shaft seal too. If everything seems okay, I'll leave it for now. Pulling just the transfer case isn't nearly as much work as the transmission.

 

[410Fortune]

Nope It’s not!

I have never rebuilt a 4406 just sayin
I’ve been running them for years
I never know how many miles are on them because they all come from junkyards and usually they are already pulled or the trucks they come from have digital odo

I’ve seen how they wear out inside and how they are rebuilt.. I guess I’ve just been lucky. Not one noise, not one issue and no real leaks aside from the rear drivelines seals wearing out

You are doing great! Soak those stupid header bolts

 

[97Sandbox]

One busted knuckle (and miraculously no broken extensions) later and the passenger downpipe is free. Both downpipes are out and I pulled the 4406.

The rear seal was dry before I pulled the rear driveshaft and the front seal is bone dry.

It looks pretty dry under the front output shaft too. The only oily areas are under the shifter shaft and around the VSS (which is unused in my '99).

Everything spins smoothly and there isn't any bearing play that makes me concerned. Based on all that, I don't think the two slight leaks warrant a rebuild. I'll just live with the leak around the shifter (range selector?). Can I just pull out the old VSS and make a block-off plate, or does it engage something inside that'll be unhappy with the sensor removed?

And with that, the next item to come out is the transmission itself! Well, starter and crossmember actually, but you get the idea.

 

[410Fortune]

You can remove sensor and make block off plate no harm
Your plastic vss driven gear rides in a plastic drive gear
They won’t miss each other lol

Get a new t case gasket for when it goes back together

 

[97Sandbox]

You mean the paper gasket between the case and trans? I've got one of those ready.

 

[97Sandbox]

It's out! New thread coming in the transmission section where we walk through this 4x4 M5R2 rebuild along with a 2wd that's destined for my Sport.

Which reminds me, I need to make a copy manual swap harness while I have this one out for reference:

My 4.2 clutch looks normal, as it should.

And it appears my re-torque and dab of silicone did not cure my oil pan leak.

Oh well, that's something I'll address whenever this engine has to come out

 

[410Fortune]

Sure it’s not the rear main?

Looking good can’t wait to see you rebuild it so I can cheat and copy you

 

[97Sandbox]

It could be. But that seal is brand new Fel Pro I installed when I did the initial swap last fall. If it's leaking already, I'd expect another new one would do the same.

 

[97Sandbox]

Here's a link to the trans rebuild thread.

 

[amj441]

Based on where that oil is sitting, could it be from the pan? looks like the corners of part that kinda lumps over the crank may be leaking there as that has to have silicone added to the corners.

If it were the main wouldnt it be all over the clutch?

 

[97Sandbox]

Yes, I do think it's likely coming from the oil pan gasket (which is original from '99). Before I put in the clutch, I scraped off the crud, sprayed out the residue with brake cleaner, smeared on fresh ultra black, and re-torqued the pan in effort to stop the gasket from leaking. Looks like that wasn't enough. It's annoying, but not worth pulling the engine for.