The 4.0 Swap was chump change compared to this - Look inside...

[rookieshooter]

Could you do some kind of spin on what i did to make a gasket for the tranny fluid pickup? Even if you just took some thin cardboard like a cereal box. layed over holes and tapped with ball peen hammer and then transfered those marks to the new plate. Then use the right size transfer punch and mark. Or if you got a good eye, just take a steel punch and mark it.

 

[janderson4010]

Ive been making gaskets for a long time, started when I was 14 working on dirt bikes lol. that's what I should have done, but I got myself in a big damn hurry. I'm going to take the remainder of the 1/2" plate I have over to the shop tomorrow and see how hard it will be to just make a new plate, with the holes drilled in all the right places, and hang the other one on the wall as a reminder to slow the hell down. live and learn I guess, but yeah Rick your right that's exactly what I should have done.

 

[janderson4010]

got a little crazy with the die grinder and made my own countersinks lol, once I had them roughed in I put the bit I bought in there and smoothed them out, ill post pics tonight but that part is done

 

[janderson4010]

ok so I got the countersinks done on all 4 bolts, you can see that 3 are off center of the hole but they are all countersunk straight in relation to the holes. I took the planetary set off of the main transfer case and marked the holes for it, they are all in the right place thank god. So I just need to drill and tap them and its time to clearance the case for 2 of the bolts that mount the planetary set to the plate. then final assembly.

also went to the steel place and got 20' of 2x4" rectangle tube with 3/16" wall thickness and their last 3 sticks of 1 3/4" .120 wall tube, have to buy 2 more sticks when they get some in, probably get a stick of 1 1/2" for braces and stuff too. after the doubler is in I can start the body modification, the bottom of the body should be about 2" below the bottom body line.

 

[janderson4010]

getting closer and closer, ended up making the bolts holding the planetary for the tcase 7/16" instead of the 3/8" that the trs guys did, mainly bk I screwed up the first ones and wanted the others to match. Just got to go get bolts and I can start the mockup assembly, just make sure everything goes together before final assembly and install.

 

[janderson4010]

went and got bolts, I realized that the 5th bolt would be inside the case, and it has no room for it in between the planetary and the main case, so I ground out a countersink and picked up a allen head bolt that would sit flush with the planetary case, here are some pics, im getting pretty damn good at countersinking bolts with a die grinder haha.


you can see the counter sunk black bolt no the side there

and here is where the bolt head would hit on the main case

here it is all bolted together;

 

[janderson4010]

who thinks the unused shift indicator would be a good fill location for the doubler case? I already know it takes about a quart of fluid.

 

[Heath]

:mattmoon:

 

[janderson4010]

:mattmoon:

your opinion is poop

 

[rookieshooter]

Seems perfect to me. Or just pull off the vent tube off of that vent fitting and use one of those pump type gizmos.

 

[janderson4010]

yeah im sure thats how its going to go down, maybe ill get a plug in place of the sensor, of course it makes a plug thats just fine, and its free. getting closer and closer to 6.25:1 reduction, its gonna be awesome. Rick what was your atlas? 3.8:1?

 

[rookieshooter]

yeah im sure thats how its going to go down, maybe ill get a plug in place of the sensor, of course it makes a plug thats just fine, and its free. getting closer and closer to 6.25:1 reduction, its gonna be awesome. Rick what was your atlas? 3.8:1?

 

[Heath]

All that gearing and he still won't be able to pull me out if/when I get stuck... UGH... Why do I keep you around again?

 

[rookieshooter]

All that gearing and he still won't be able to pull me out if/when I get stuck... UGH... Why do I keep you around again?

So he has someone to pull him home once the Dana 30 lets loose with all that gearing. Or to yank him back up out of a ditch once he realizes it won't stop like it used to.

 

[janderson4010]

All that gearing and he still won't be able to pull me out if/when I get stuck... UGH... Why do I keep you around again?

Heath I keep telling you that you can't get stuck in the mall parking lot man. If you do ill come pull you out in my f250, I seem to remember using a similar truck to pull out your excursion at one point.

 

[janderson4010]

So he has someone to pull him home once the Dana 30 lets loose with all that gearing. Or to yank him back up out of a ditch once he realizes it won't stop like it used to.

yeah I need disks in the back and an excuse to build that d44, if the 30 lets go I guess ill have my excuse haha. but im thinking ARB for the front, and we all know how long thats going to take me to get cash for.

 

[janderson4010]

just have some grinding for wrench clearance and it will be good to put together.

 

[rookieshooter]

Calm down, calm down I think your getting nervous.
Nice to sit back and see others wrenching on their rigs.

 

[janderson4010]

im getting a little antsy I can tell you haha, i want to go sloooooooow

 

[janderson4010]

I know where a 8.8 with disks is, im gonna try to pick it up, actually know where 2 of them are, one is 200 bucks the other is price tbd. hopefully some trade work will get me set up. Started grinding the plantary for the rear case, I think at this point it will be a better option to modify a wrench to finish this out rather than weaken the case, there is a lot of material that has to come out for it to fit the open end of a wrench, but if i grind the box end so that its smaller it would fit right on there. guess ill see what I come up with.