Old Ugly, New Clutch

[GHarman]

Thanks Tram, I appreciate your well wishes! Will be pluggin' away at this little monster in the late AM till dark, tomorrow. What I dont get done tomorrow will get done another time . GregH

 

[GHarman]

Good, Bad, And Ugly

 Or; The more I get into this, the more I dont know!

Me and my buddy crawled under Old Ugly and what do we find? You all already know, im sure:-laf. That front cross member is riveted to the frame on both sides. So, the question is; Do we support the motor, loosen the motor mounts, and drill out the rivets, jack up the motor to clear and then remove the cross member and motor mounts. The question is not about; " can we remove the cross member". It is really; " should we remove it?" It will require a very precise hole realignment and "0" clearence grade 8 bolts, washers and nuts for reinstallation. Will this be as strong as the factory assembly? From a highway useage perspective, maybe. For 4X4 usage, I personally doubt it. To further complicate this scenerio, this frame was bent in a front end collision in 1995. It was straigtened. Will there be a stress loading that we will have to overcome with clamps and jacks? The engine will be in the way of directly attacking the frame. I could weld a couple of braces on the frame before disassembly? More junk in the way and more dominoes to fall!

I would think Cummins will attack this from the front end by removing everything from the grill through the intercooler and radiator, draining the coolant as well as the oil and parting the drive train where the transmission bolts to the clutchhousing (or clutch housing to clutch housing adaptor plate). The lift would be forward, up and over the cross member past the front frame cross brace and bumper. I imagine they have a specialized engine stand.

Any of you Pro-Mechanics or Hobby builders have any suggestions. The removal of the engine is beyond my physical capacity and equipment available, even with my Bud doing most of the work. Replacing the frame member rivets with bolts and realigning said frame member is my "Bad" that could get "Ugly". This is decision time, my pride does not enter into this. Winter is here @ 9000' elevation and time is short. I would like to do this myself, but I do not have the luxury of a reliable backup vehicle. "Whaduya think". GregH

 

[GHarman]

Try to Think outside the box

OK, ferget what I said, above, fer a sec. What IF? I/we remove the rear transmission mounts and drop the transmission down onto the frame member in the rear. THEN lift the motor, from the top to clear the motor mounts? A change of angle of approach? Just some midnight engineering :-laf out of necessity here. Gonna request input on this subject in a new thread . GregH

 

[GHarman]

Summary, Lessons learned.

This job has been a rough one because of two things: assuming and lack of communication. I accept all the blame fer these issues. In an effort to get things done right you must train and very closely supervise your help. We got in a hurry, cant do that! I made only one written list. Should have made a written list each day work was done on the truck. I assumed to much! Should have made points of procedure.

Cleanliness was another issue. I am not or ever will be a shade tree/mudpuddle mechanic. Ifn I ever have to bust into a drivetrain again I will pop fer a thorough under the truck steam clean of all drive train components and the frame members. I dont know how much time was wasted cleaning each component. Will future damage be caused by dirt contamination of gear boxes?

This was a slow process based on limited resources and limited physical capability with a truck that has been pretty much neglected other than basic oil and filter changes, application of grease and valve adjustments. ( My wifes car received most of the attention. )

Hopefully we will be on the road soon. I really appreciate those of you that have provided input and encouragement. Couldn't have done this without you. Thats why I like TDR. GregH

 

[GHarman]

Part numbers for R.M.S retainer

Original number on rear main seal retainer is; 3921043. New Cummins number is; 3936904. GregH

 

[GHarman]

Howdy out there!
Update on an old post! OLD Ugly is being Resurrected, New Ugly gets the South Bend Clutch from Old Ugly, the LUK clutch and flywheel will go into the '91.5. Two trucks will be running soon.
One of my Young Friend's was in a bind and we are working together to keep these old trucks on the road.
Lots to do.
Just thought I would check in and see if there were any 1st gen aficionados left on TDR?? New Ugly passed the required emissions test, last month.
After the clutch swap, this weekend, the goal is to get the rear axle pod, rebuilt. Old Ugly is getting a bunch of work done to make it roadworthy until further replacement parts can be procured.
Regards!
GregH

 

[RWherley]

Well lets see so photos of these projects

 

[GHarman]

Well lets see so photos of these projects

I'll take a few tomorrow and see if I can get them downloaded on the computer in a few days.
GregH

 

[GHarman]

Todays update!
Both clutches swapped out. I definitely prefer the South Bend Con-O over the LUK.
Took some pictures. If ya seen one You have seen 'em all! I don't breakdance under the truck any more.
Grease and oil changes. My Young Friend did the grunt work. We did notice that these transmission stabs were difficult at the pilot bearing/bushing. Very snug fit.
Course, everything was done on the ground with some cribbing and jacks. We do not have access to a lift. Thankfully, we do have a transmission jack!
Old Ugly seems to have a Castor/Camber issue on the damaged spindle. That Warn Hub was cracked.
GregH

 

[MMeier]

Welcome back, got mine in paint finally last fall. Still hoping to get some 35's under the thing !!

 

[GHarman]

Welcome back, got mine in paint finally last fall. Still hoping to get some 35's under the thing !!

Thanks! Ive been lurking about. To busy to spend as much time here as I did in the past.
May be looking for a complete Dodge Dana 60 front axle, 3.54 gears. In case the front axle in Old Ugly is toast.
This original axle on the 91.5 is not a 4500# axle. It is a 4050# axle. Is this a Dana 61?
GregH