Return from Truckhaven first run fall '08

[Tbars4]

...Even though I missed this Truckhaven run, Today was Xmas for me...

...I want to thank TDavis for the Tire...RockRanger for getting the tire all the way down here and then to Truckhaven...Froader for getting it home to the O.C, passing it off to Spotterguy.... and Spotterguy for taking it and meeting me at PaulB's shop...

...Dannyboy, props to you for also sending my tools back from Scottsdale...

...Thank you all...

btw, anyone with a 15x10 or 15x8 5x4.5 want to trade for a chevy 6 lug spare wheel???

 

[BKennedy]

I finally got under the Explorer to see what I could see. I discovered that the rear transmission mounting bolts, where it goes into the Advanced Adaptor for the NP231 transfer case (which is also bolted to the rear cross member), had backed off so the rear mount was loose. After I dropped the linkage and drive shafts, I could shake the transfer case from side to side and up and down a few inches at the rear, it was that loose. I can't tell if the bolts just backed off and got lose, or were pulled out of the aluminum housing for some reason. I could not get it out tonight because I forgot I need a deep 9/16 socket to get the top two nuts off the transfer case.
I'm guessing it put side pressure on the output shaft and toasted the rear transmission bushing, which caused the fluid to pour out. The rear of the transmission is supposed to be wet, but not that wet. Fluid is not under pressure at the back of the transmission, its just supposed to seep out to keep the output shaft lubed.
I am going to finish up pulling out the transfer case, then tow it over to Poway Transmissions so Eldon can have a look. He doesn't charge for looking. I'm guessing I am going to leave it there if the output shaft bushing is damaged because I don't want any part of splitting a transmission case in a failed attempt to replace a bad bushing, then end up taking it over to Eldon anyway and paying him more money than I would have in the first place.

 

[dblake79]

I hope it not too bad, I just replaced my output bushing about 2 weeks before the trip to truckheven from a leak (that is also how I found out that manuals take ATF lol) glad to here it was spoted on the trip before you dropped the hole thing in peaces.
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[Dannyboy]

I know the feeling Brian, don't know if you remember the TDS '08 issues I had in the Ranger but the tranny became unbolted and caused my havoc.

 

[BKennedy]

Well, I got the transfer case and the AA adapter out today. It looks like the transfer case side was tight and sealed up very well. For some reason the four allen head bolts that bolt the adapter to the back of the transmission had backed off, then pulled out of the aluminum housing. Its missing the last 1/3 of the threads pretty uniform for all four holes. Now I have to figure out how that happened, then find out if they can be sleeved. I think the bolts were a little too short (they came with the kit from Advanced Adapters), which did not allow enough threads to come in contact with the bolts.

Or maybe the synergy bushing on the bottom of the adapter that mounts to the transmission cross member was too flexible, allowing too much movement, which caused something to go. Or maybe a combination of all of the above.

The good news is the output shaft looks real nice and clean, with no dings or scuff marks. Ditto for the output shaft bushing. I think we (me and the transmission guy) were wrong in thinking the rear of the transmission is not under pressure because there are lube ports in the housing, which could mean nothing is damaged as far as the transmission insides go. I am going to tow it over to Poway Transmission next week sometime and have him take a look, maybe pay him to put it back together and sleeve the bolt holes.

I was also thinking I might have a loose engine mount which moved all that stuff around and put too much torque on the rear of the transmission, which popped the bolts. I used a pry bar and nothing seems to move up front, but how can you tell? Maybe I should just replace them with those sleeved steel jobbies they sell at AutoFab for an insane amount of money.

 

[BKennedy]

I think I got this figured out. I think (lots of "I think" in here) there is supposed to be something called a "transmission torque arm" at the rear of the transmission to keep it from twisting too much, like the Jeeps have. I don't have one of those. The twisting on the rear of the transmission might have been too much for those aluminun bolt holes to take, which pulled them out of the housing. I am hoping this is it, because I can fix that problem with some minor fabbing.

Anybody ever sleeved an aluminim transmission housing?

 

[BKennedy]

Oh, and it appears the bolts supplied by Advanced Adapters for the kit are a little short, only contacting about half of the threads in the transmission.

 

[IZwack]

I'm not exactly sure I fully understand the situation but if the transmission is torquing over, I would probably put the mentioned "torque arm" at the engine unless there is a place on the transmission housing specifically casted for such an arm.

 

[RockRanger]

If your case ends up trash and you need a new core I will sell you one cheap (couple cases of DP) . I at one point was going to swap it into my truck but I got the doubler instead.

 

[BKennedy]

I'm not exactly sure I fully understand the situation but if the transmission is torquing over, I would probably put the mentioned "torque arm" at the engine unless there is a place on the transmission housing specifically casted for such an arm.

The mount for the transmission/transfer case on the crossmember is only a few inches wide at the bushing and I have never like it. Sure, its easy to R&R the transfer case, but I would rather not and have it stay in one piece. Jeeps have an offset bar mounted to the crossmember with bushings that won't let the transmission twist at the transfer case.

 

[RockRanger]

Jeeps have an offset bar mounted to the crossmember with bushings that won't let the transmission twist at the transfer case.

Jeeps like to shear these off on the rubicon when you are running 100 to 1 gearing. Tracy and I sheared it when we toook her jeep across the rubicon. I would do something more beefy then the way jeep has it.

 

[BKennedy]

Jeeps like to shear these off on the rubicon when you are running 100 to 1 gearing. Tracy and I sheared it when we toook her jeep across the rubicon. I would do something more beefy then the way jeep has it.

I saw a Jeep mount on the internet. It looked real thin. I was going to make one out of 3/16 channel and box the ends. I got some good advice about using a heli coil to repair the damaged threads and make it stronger than before.
http://www.explorerforum.com/forums/showthread.php?p=2054695&posted=1#post2054695
I am going to complain to Advanced Adapters and see if they will send me some longer bolts as they might be hard to find. I might just have this fixed in time for Thanksgiving.

 

[IZwack]

 

[Tbars4]

..IZ, thats what it's all about...:biggthump

 

[Burns]

IZ you so crazy!

 

[BKennedy]

IZ you so crazy!

DITTO!
But........."Truckhaven" is one word.:

 

[IZwack]

LOL it is not, you're lying you liar.... :

 

[cybergasm]

Yes it's Truckhaven

 

[BKennedy]

Yes it's Truckhaven

See, I told you. You should have done a little research.:

 

[IZwack]

See, I told you. You should have done a little research.:

LOL cyber is in on it, you probably paid him... or "took care" of certain parking ticket.

Your dog is looking festive BTW -- love that little hat. Too bad my turtles are boring, they just sit around all day and observe the world.