Tranny Swap has begun (518-360)

[Subliminal]

Well, I spent some more time yesterday on my project...on my favorite part: Under the dash.



If you look at the top right of that picture, where the aftermarket wires go through the big rubber grommet and into the cab...well, that's where the clutch cylinder goes. DOH! Of course, one of the wires is for my pyrometer and the instruction manual talks about not cutting those wires, and resistance changing the readings. So, I got a little creative...and this is how it turned out:



Basically, the clutch is mounted to the bracket you can see through that hole...so the firewall isn't really structurally necessary to the operation of the clutch. So, I broke out my drill, my dremel my tinsnips, my files, my electrical tape and my zipties and I notched the side out, put massive amounts of electrical tape around everything the wires/boost tube would touch, and moved them out of the way. I then bolted up the clutch bracket under the dash and called it a night...

Again, it just cracks me up how the little things in this project can take the longest time. I had all my acc. wires running through that hole. Underneath the dash I ran my aftermarket speaker wires through the bolt holes for that bracket, so those had to be moved, too.

At any rate, I should have the pedals mounted this evening, and after that it's just a matter of mounting the big stuff under the truck...well, I also need to seal the transfer case with the seal kit I bought...

[ShadowFromHell]

So your putting a 4spd in that truck? Good luck going down the freeway. I have a 90 CTD with a 727 and its maxed out at about 80 mph with 3.07 gears.

[Subliminal]

LOL.

Alrighty.

5 Speed, son...manual not automatic. Your 727 is just the non-OD 518...although I'd think you'd get better than 80 with 3.07s. That's pretty high gearing.

[ShadowFromHell]

stock pump, no tach. It may go a little higher but I dont want to find out!

[Subliminal]

These trucks are governed by fuel cutting out at a certain RPM. Stock is around 2800 rpm. You can keep your truck in neutral and hold the pedal down and it won't run much past that 2800 rpm. You can't hurt it by topping it out...just fyi.

[Subliminal]

So, I took a half day today in hopes of finishing my project.

I:

Installed the pedals
Installed the clutch cylinder
Installed the transfer case
Installed the crossmember

Then I went to install the rear driveshaft.

The front went in nice (although in the pic I think she's a little too tight):


Then I got to the back.



Dang. My donor truck was a cab/chassis truck, but I thought I measured it the same. Guess I was off...about 2 inches. Grrr.

So, work on hold, off to the driveline shop tomorrow (hopefully).

[glhs0426]

A little late to the party; looks good. You know Johnny makes those T-case bushings in poly

http://polybushings.com/pages/1604.html



BTW, you have a pm.

[Subliminal]

Woo Woo!

I drove it around the block. Ran and shifted good!

Also, the first time I started it up after over 2 months, it started within the first revolution and ran like a top!

I still have some issues to iron out, mainly with wiring, but dang...feels good!

[mcsvt]

Nice!

[onerippinturbo2]

congrats dude!!!! glad to hear it's up and running!!!

[jory]

Good job! been watching this thread, 5 speed swaps are great I bet that diesel feels like a different machine. I would do that for sure if I bought an older truck that was auto (thought about it many times)

[Muertoloco]

ooo.......i thought this thread was about something else....

[Subliminal]

So, I called the good people over at Phoenix Friction products.

Actually, I emailed them this:

Hello!

I finally got my truck back together and it appears I have a serious balance issue with the product I purchased from you below.

I get a vibration in my driveline that was not there previous to installing this new clutch. The vibration is noticable at idle, but more noticable at a little higher rpm. The vibration happens with clutch in, clutch out, in gear while driving, and while in neutral revving the engine. It is also VERY noticable when downshifting.

I REALLY don't relish pulling the trans again, but I can't see a vibration such as this being good for the engine or transmission bearings.

I'm hoping you folks stand behind your products and/or maybe have an idea.

Thanks,

They called me back within an hour. The guy knew the history of the Sachs pressure plate and the contract going to Luk and the size change and blah blah blah.

Basically, his thoughts were that everything has tolerances...the pressure plate has a tolerance for how out of balance it can be, the flywheel has a tolerance and so forth. His guess is that I just ended up having all the bad spots lined up into one area...sort of a perfect storm.

His first recommendation was to take it apart, turn the pressure plate 180 degrees and try it again.

Silence on my end. Then a big sigh.

I think he felt my disdain and then said that if I pull the pressure plate and the flywheel, they'll throw it on their machine and check the balance for me, and fix what needs to be fixed, assuming it needs it.

Of course, the very thought of pulling that contraption apart again is NOT appealing in any way/shape/form.

Especially considering I just gave back the tranny jack I borrowed. Grrrr!

On the bright side, now that it's my second run at it it should take significantly less time than 2 months.

[glhs0426]

If you hurry the bolts won't sieze like they did the first time.