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T-150 Trans & Dana 20 T-case Rebuild

BrockGrimes said:
Thoughts on the worn gear?
Click to expand...
I missed this post. That is typical for the output shaft gear and I wouldn't worry about it. Mine looked the same (as it did years ago). They almost always wear that way as they are engaged 99% of the time and usually have all wear on the same face.
 
CJ said:
I missed this post. That is typical for the output shaft gear and I wouldn't worry about it. Mine looked the same (as it did years ago). They almost always wear that way as they are engaged 99% of the time and usually have all wear on the same face.
Click to expand...

So it looks good to reinstall? I was mildly concerned, but was gonna reinstall it anyway as money is getting tight lately.
 
BrockGrimes said:
So it looks good to reinstall? I was mildly concerned, but was gonna reinstall it anyway as money is getting tight lately.
Click to expand...
Shouldn't be any problem. Remember, that shaft is engaged anytime your rear wheels are moving. It is always wearing... :)
 
Ok been a bit work and money has been keeping me down. No longer.
Got everything painted and have started reassembly of the Transfer Case .
I've got all the gears back in it and the shift rods (PITA) they go back in,
in a certain order and no other way. You have to get one shift rod in line so these interlock pins
inside both line up and then the other shift rod will go right in. Novaks instructions tell you which
one and how if you read instructions, LOL. Going together fairly easy, gota check my end play and
make sure I have the right shims, etc and it'll be done. Oh I coated the hell out of the needlebearings
with vaseline didn't use a rod to hold them in and the intermediate shaft went right in no issues. But when
your doing that part it looks like it's gonna be hell, and things get messy. Anyway's pic's to come.
Then it's on to the Transmission .
 
Sorry for the lack of pic's been working me arse off.
I'll try to get them up today. The Transfer Case is assembled and the Transmission is torn down awaiting parts. I'm replacing 4 gears, misc. bits and the entire clutch linkage, so yeah about $500 worth going into the Transmission . Parts should arrive next week.
I'll be one the road Sat. I hope! Wait forgot I need to install a clutch to, dang it, LOL.
For those who don't know a 1979 CJ5 has 1 of 2 clutches ones like a 10.5 and the other an 11, so you have to
take measurements of your old one to see which on you need. My bellhousing and clutch etc. is still bolted to the motor.
Guess I need to pull that out and get a measurement.

BTW, can the motor be started if I pull the bell housing and clutch and just leave the flywheel?
It's been awhile since I started the jeep. Dang forgot I'm gonna get the flywheel checked also,
so maybe this weekend I'll be on the road, we'll see.
 
Here are the pic's I promised:

Hmmmmm....What's inside a T-150 Transmission ?

dsc04925.jpg


This is a very worn reverse idler gear:

dsc04947.jpg


Empty Transfer Case , and all the gears layed out:

dsc04937.jpg


Very sophisticated tool for removing the larger nuts.
It's a scrap piece of angle with 2 holes drilled in it then it's bolted to the
2 lower holes in the Transfer Case , a large socket, breaker bar, and cheater
and off comes the large nuts.

dsc04933.jpg


Appears to be some teeth missing from the lower gear (1st):

dsc04943.jpg
 
Well the parts fairy in the brown truck made a delivery.

$500+ later and I have:
Transmission MOUNT 1976-1979 RED - $24.99
Transmission Torque Arm Grommets (2) - $5.99
Motor mount - $45.99
MAINDRIVE-THIRD GEAR - $93.99
SYNCHRONIZER ASSEMBLY - $104.99
FIRST GEAR - $59.99
REVERSE IDLER GEAR - $74.99
PIN-SHAFTER-REVERSE IDLER GEAR - $0.99
Clutch linkage KIT 1976-1986 - $59.99
Jeep T-shirt - $20

So building begins again, I hope to have it on the road this weekend, still need a clutch and flywheel checked. But once it's finished it'll shift smooth (I hope).
 
Every gear in it needed replacement, all the small teeth are gone, the PO musta used reverse as the brake. Upon cleaning it out I found about a tablespoon worth of powdered metal, and all the bearings are, well well worn. So I'm basically replacing everything but the case, LOL.
 
Well I seem to notice that you have been having as much fun as we have with taking apart everything. We have cleaned up the tranny and tcase and decided to paint them red, going with a red theme for the undercarriage, hopefully it comes out right. We got the transfer all the way disassembled and are putting everything back on this weekend. I haven't taken any after pics yet, but will post before we put back under. Curious question for you, did you have any problems reassembling the shift rods? I seem to be having a lot of issues with putting in one rod back since we replaced the oil seals. Also, did you have any problems with the intermediate shaft bearings? Those little buggers are whooping my tail!!!!! Well hopefully the end product turns out right? We are getting all of our small pieces tomorrow, new starter, ujoints, mounts and new bolts for everything. I did the undercoating with everything off, which made it nice and easy to apply, n she looks clean now :) We begin reassembly on Friday, hopefully all goes right. Best of luck to you on your rebuild. Oh I found the trick with the skid plate and the balancing act, a lot of muscle and utilizing a tranny dolly, it does wonders
 
The shift rods have to go in in a certain order, the grooves in the shift rod have align so the interlocks move out of the way for the next shift rod coming in. Drop a note to novak with your tranny type and they can tell which order.

As far as the intermediate shaft put a thick coat of vaseline on the needle bearings, they should stay in place long enough to get the shaft in, if not look in the above posts CJ used a socket as kind of a place holder it holds the bearings then the shaft pushes it out and the bearings stay in place. Use vaseline not grease, the vaseline with mix with your oil and not cause problems, grease wont. I used gear oil and vaseline as assembly lube.
 
You could probably decrease the amount of elbow grease needed by replacing the simple hose with a power washer. Looking good...keep the pictures coming!
 
Nah here the clay gets mixed with the grease on the Transmission and Transfer Case and turns into a brick, water has no effect on it. Most of the grime removal was done with a flat head screw driver, it was a real PITA. Right now I have all the parts but the clutch.
I'm at a stand still until I can get some decent snap ring pliers, there is a ring that goes on the clutch shaft, and it has no holes for regular snap ring plier and the ends are cut at an angle so no go there, it's the hardest thing I've had to deal with so far. Had me cussing, almost throwing tools, gotta hit up sears or Tractor Supply to find a tool to help get that ring on, then i'll be back in business. More pic's to come.
 
All the pic's are on here except the installed product.
I had to pick up the pace and spent a couple days jamming on it to get it back together, so didn't get reassembly pic's but it's pretty much a reverse of the stuff above. The only issues was installing the roll pins and making sure to keep the needlebearings in place. I misc. pic's I can add but didn't post int he thread as they didn't add to what I was discussing.
It went together pretty easy, easier than the Transfer Case . The only issue I ran into was a small leak between the Transmission and Transfer Case and had to adjust my new linkage.
 
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