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Author Topic: SquareD Part 5: The build continues and gets more aggressive  (Read 267430 times)

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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #50 on: October 28, 2014, 09:14:37 PM »
Then after some magic with the adjusting nut, one of the bands slips out

This one shows very little wear for 171,000 miles behind a diesel
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #51 on: October 28, 2014, 09:17:01 PM »
The Chrysler manual is excellent, like 10X better that that wimpy ATSG. The Chrysler manual shows a picture of everything, where the ATSG will say remove the snap ring from the governor unit...OK, what is a governor unit??? Factory book shows it, shows the snap ring and shows how to get to it
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #52 on: October 28, 2014, 09:19:34 PM »
Next the gear drive unit comes out. Normally Dodge uses a 3 pinion unit, this truck had a 4 pinion aluminum unit. I will be replacing it with a 5 pinion steel unit for a whole lot of extra strength
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #53 on: October 28, 2014, 09:21:23 PM »
Then the second band and that sun gear comes out leaving very few parts remaining
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #54 on: October 28, 2014, 09:22:44 PM »
A couple more bolts and a snap ring or two and you are left with an empty case
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #55 on: October 28, 2014, 09:24:08 PM »
You may recall I had broken off a cooling line fitting some months ago. I used an easy out and the threaded part came out, well, easy!
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #56 on: October 28, 2014, 09:25:43 PM »
Without further adieu, disassembly of the overdrive unit commenced
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #57 on: October 28, 2014, 09:27:18 PM »
The book is straight forward, one just needs to pay attention and follow step by step
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #58 on: October 28, 2014, 09:31:50 PM »
Next up was a thourgh cleaning.

First everything was soaked with the purple cleaner and allowed some time

Then I scrubbed the cases inside and outside, finishing with a rinse of scalding hot water.

I redid the cases a second time getting every spec of dirt there was. All I was left with was some staining and paint residue. I'll do some light sanding tomorrow prior to painting with acid etching primer, then top coating with Nason acrylic enamel in appliance white. I figure white will show up leaks better and in the reduce light of the underworld where it will soon live be easier to examine for maintenance checks
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #59 on: October 28, 2014, 09:32:59 PM »
And that is the garage situation at the end of build day 179
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Offline Dawg25385

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #60 on: October 28, 2014, 10:24:27 PM »
Awesome! Coming along nicely!
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Offline KensAuto

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #61 on: October 29, 2014, 10:21:55 AM »
Not to backtrack, but when you made new brake lines, did you bypass that horrible abs valve like we talked about? The pic on the last page showed it still hook up (on one side).
...and , how come part 7 isn't stickied? I just noticed part 6 is runnin' off the charts with visits, this one not so much.

Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #62 on: October 29, 2014, 12:45:12 PM »
Ken the ABS has gone the way of all useless things...

It was in the back located in the frame rail on the left side. It got replaced with that adjustable proportioning valve

As for sticking part 7, well, we are back to normal here with discussion going to whatever direction the DOT's drive it...Don doesn't care.

I'll just post up the build, probably through engine and transfer case install, all the way to running, then we will start part 8 with the bumper builds, armor, fuel tanks, antenna and camera masts and stuff like that...
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Offline KensAuto

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #63 on: October 29, 2014, 01:27:55 PM »
Gotcha...on all counts.

Offline Drunksailor

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #64 on: October 29, 2014, 02:03:41 PM »
Im happy Square D is back in motion and even more happy to see a "Big Don" tear down of a trans. Looking good and I'm glad your knee is doing well brother, I'm sure the recovery is ongoing but at least your a mobile old salty warrant again ready to snap heads at a moments notice. ;D
-Seth

?Anyone in any walk of life who is content with mediocrity is untrue to himself and to American tradition.?
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #65 on: October 29, 2014, 02:27:34 PM »
but at least your a mobile old salty warrant again ready to snap heads at a moments notice. ;D

You're darned right
So get it squared away there Sailor!
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #66 on: October 29, 2014, 06:47:38 PM »
OK, let's kick this transmission can down the road a bit further.

It may not look like much in picture time, but in RBDT (Real Big Don Time) it took over 5 hours of detail work to get to the end state.

I had set a goal of getting the cases painted and the overdrive unit torn down and cleaned...but life intervened.

I get this call from the school. The larger pre-ranger has managed to projectile puke all over himself, his desk, his books and several of his closest friends.
No one is amused and wants me there five minutes ago.

So's eyes fire up the trusty V-dub and away she goes. Sortly thereafter I hear stories of a massive viral infection spread all over the community by my son who is likely showing the first stages of ebola.

Si I get him out of there and note the boy is healthy! Like really feeling good. He is talking about getting home early and taking the red dog for a run...yea, something's not OK in the kingdom.

So while I'm running down the list of questions, I determined he has not done a field trip to Liberia, or met with any people with an accent or anything like that. What he DID DO was to study about blood....yea

You see, he is one of those guys who passes out at the sight of it. One day my neighbor, a doctor invites him to make the rounds with him, since the larger ranger was considering a career in medicine. Mike my buddy, the Doc finds out early on he does not like the red stuff.

So did (Me) takes my son with me the next time I'm giving blood. He watches the needle go in, witnesses the pulses of his daddy's heart when the red stuff fills the tube. I am watching the nurse, then I look at my son who is a white boy. I mean he is like totally white, no other color. Then I watch him change from white to green. THen I watch as he mimics a giant sequoia doing the death fall. The floor was a soft padded linoleum tile which he thumps off of before anyone can get to him.

It took awhile to get out of there. Another Dr. visit checking for signs of concussion, and that was after maybe 20-30 min of my boy being in a near passed out state of nausea and total dizziness.

Yup, Blood, not Ebola. So we're having Chili for dinner...red chilli ;-)))

OK what were we talking about?

Oh yes, Square D

So I cleaned on the transmission for a while longer
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #67 on: October 29, 2014, 06:49:53 PM »
I used the wire cup grinder thing, a hand held, a tooth brush sized one. I used purple stuff, 180 grit sandpaper, a scrapper, some choice words, and a little voodoo, and in the end the nasty oxidized aluminum gave it up for some shinier stuff
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #68 on: October 29, 2014, 06:53:05 PM »
Then the machined surfaces were taped off
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #69 on: October 29, 2014, 06:54:42 PM »
Next I sprayed the virgin aluminum with the acid etching primer
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #70 on: October 29, 2014, 06:57:07 PM »
You can bet your last nickel that primer burned in pretty well.

Here are the pieces parts about to become as white as a wedding dress!

You might note the cast deep sump oil pan showed up. I was sanding on that for a fort-night (Is that like a long time??)
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #71 on: October 29, 2014, 06:59:04 PM »
Then the first of three coats of the white Nason acrylic enamel with hardener
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #72 on: October 29, 2014, 07:00:16 PM »
And after the third coat:
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #73 on: October 29, 2014, 07:06:14 PM »
Well that got me to nearly 1800 and the end of another build day

But before we set the sun on this exciting episode (Not really) let's play parts!

Who wants to play parts?

Anyone?

OK, you over there with the flip flops on!

Let's look at the new steering crossover assembly

It features DOM tubing not that cheap ole stock crap, nossir this stuff is certified to kill all varieties of jap and kolean and even chinaman kars! Schweet!!!!!!!!

But the reason Big Don bought it was to pea off the old lady, (She doesn't like parts unless they are small, sparkle, and cost a really lot!) no, wait that's not right, I needed it, yea, that's it, I needed this part!

It has offset tie rods that move the bar out board a tad bit...and I'll show you why that's important
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #74 on: October 29, 2014, 07:09:57 PM »
Remember that big ole mo-hunkin front diff cover Shawn supplied me some time ago?

Well it sticks out far enough to almost interfere with the steering, the factory steering angles, that is...

Does Don leave anything factory? Anything?

Point made. I have messed with the steering angles bumping it up a bit, and just enough for that factory junky cross bar to nick my prudy paint on that cover of Shawn's.

This will buy me valuable space that will make me happy and I'll sleep better tonight, and if the truth be known, so will U!
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #75 on: October 29, 2014, 07:12:05 PM »
And that boyz and girlies is the end of yet another build day in the seeming-lee endless progression of these expanded oil-change related activities!
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Offline KensAuto

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #76 on: October 29, 2014, 09:20:08 PM »
Man, I never get enough of that end-of-day money shot. Really like that color on that truck.

Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #77 on: October 29, 2014, 09:43:04 PM »
I've been toying with the idea of splashing that color onto C-Max as well...
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Offline Dawg25385

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #78 on: October 29, 2014, 11:05:08 PM »
I saw some pics the other day of some intercooler pipes and turbo housing that somebody had done in OD... Looked AWESOME
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #79 on: October 30, 2014, 08:29:47 AM »
I saw some pics the other day of some intercooler pipes and turbo housing that somebody had done in OD... Looked AWESOME

I believe there were some studies conducted
The results were astounding. The smartest people prefer the color green most of all, did you know that?
And the smartest and better looking of that group prefer the subdued greens!
Yep, proven fact...






or not....
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #80 on: October 30, 2014, 08:18:16 PM »
OK, it's past 2000 which is past "O"-dark-thirty for all you civies out there who can't add.
What that means is that it's been a long day and my dogs (Feet) hurt and even more has been done to SquareD

I like how the paint flowed out on that transmission case
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #81 on: October 30, 2014, 08:21:32 PM »
The goal today is to get the overdrive torn down, create a tool to collapse that uber strong spring in there, and get it reassembled.

Granted that is an enthusiastic goal, but life is full of goals for those who actually hope to accomplish something.

The teardown is fairly straight forward following a step by step process starting with removal of this governor cross shaft
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #82 on: October 30, 2014, 08:25:06 PM »
Then I had to create a simple tool which could compress the spring far enough to gain access to the retention rings to remove them.

I discovered some old 4" exhaust tubing was the correct diameter. SO I cut off a couple of sections and welded some long 3/8" bolts to give me a "Picture window" through which to work

Here is the wicked-simple, no cost tool

In the background, the Chrysler tool is shown in the repair manual
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #83 on: October 30, 2014, 08:26:39 PM »
The thing is set up in a press.

I own an ancient 30 ton unit that somehow still works
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #84 on: October 30, 2014, 08:28:13 PM »
With some scary pressure applied, one can gain access to a big and a small snap ring and make them go away
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #85 on: October 30, 2014, 08:29:06 PM »
Then you release it and it falls apart
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #86 on: October 30, 2014, 08:30:22 PM »
Again it is just a meticulous step by step process to get the parts all torn down for inspection, cleaning and replacement
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #87 on: October 30, 2014, 08:32:57 PM »
My truck came with a 5 pinion planetary gear right from the factory. This is a heavy duty part, one that I sourced and purchased fearing I would have a 4 pinion gear. Now I have a spare!
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #88 on: October 30, 2014, 08:34:06 PM »
A couple more snap rings and the whole thing was reduced to its basic parts
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #89 on: October 30, 2014, 08:35:46 PM »
With that, the cleaning and inspection began. I cleaned everything in a vat of lacquer thinner and allowed the parts to air dry.

Next up was reassembly starting with a new output bearing
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #90 on: October 30, 2014, 08:36:28 PM »
And thrust washer
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #91 on: October 30, 2014, 08:38:02 PM »
So far I would recommend anyone to rebuild this transmission. It is simple and with the aid of a factory repair manual, all you need to do is follow the steps

The build up continues

Here I am using the "newer" 5 planet gear train
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #92 on: October 30, 2014, 08:39:28 PM »
And another new thrust washer along with a new spring plate
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #93 on: October 30, 2014, 08:42:45 PM »
The copper bushings were in great, like new condition so I didn't replace any of them!

Next up is setting up the new overdrive clutch pack.
The factory calls for 8 clutches, but I believe there is room for more. I have 10 on hand...time to skedaddle and do some reading to cipher out how many I can get away with

Note that these Raybestos clutches and steels are make in the USA
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #94 on: October 30, 2014, 08:43:55 PM »
Good stopping point, so I marked the manual and bagged the fresh parts and called it a night
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #95 on: October 30, 2014, 08:44:41 PM »
So far almost all of these parts were replaced!
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Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #96 on: October 30, 2014, 08:45:17 PM »
And here's the mess at the end of build day 181
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Offline Anthonymo

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #97 on: October 30, 2014, 10:33:40 PM »
Loving this! Thank you so much for taking the time to take all the pictures and writing it up. I've been enjoying this build since you posted it to expo!
Where did you get your factory service manual you love so much? Looms like something I should have for my 01!

Offline Flyin6

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #98 on: October 31, 2014, 07:51:12 AM »
Glad you like this, hope it proves useful...

When I bought the truck, it had a tool box mounted in the bed. Inside that toolbox were the two manuals. The large factory one, and the factory diesel supplement manual

I have used them many times!
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Offline JR

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #99 on: October 31, 2014, 11:49:29 PM »
I am impressed Don. Tearing into that puppy good!

I do question painting before being done though as you are going to get it pretty messed up putting it together and AT fluid is known for removing paint.

Which manual is that? I did a quick search for Chrysler 47r without much luck. Oh, found a grid to. Just missed a new one for 60 but got a used one for 50 shipped.
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