Transmission mating to the transfer case questions?

[needabronco]

OK, over the last couple of weeks, I have rebuilt my Dana 20, and I have been rebuilding the RAT 3spd manual trans. I have now built the trans at least 6 or 7 times and I finaly have it together right. The problem is now when I mate the two together and torque the adapter to spec's, nothing turns, I mean the thing is siezed up tight. If I pull it apart on the bench everything is good. I used Ford manuals I downloaded off the net, so I'm positive I got both together right.

Any suggestions, I need to get this together so I can drive it around while, I save up for a 700R4 swap.

Thanks in advance.
Casey

 

[DirtDonk]

When you put the three pieces together (trans, adapter, t-case) do they pull up flush with each other by hand? Or do you have to run the bolts up to pull the cases together?
If they don't mate up by hand, or at least by very little bolt torque, then something is not quite right after all.
If I remember it sould not take much to pull them up to each other.

Paul

 

[needabronco]

There is resistance between the trans and adapter. When i took the trans apart I laid everything out in order just like it came out so I know it went back together right (?). Maybe this is just a sign to pony up and do the trans swap... Although I really can't afford it right now.

 

[DirtDonk]

Almost sounds as if the main output shaft is not quite seated all the way. Like if one or more of the roller bearings fell down between the input and output shafts, or the main output bearing is not seating in it's bore.

When you look at the back of the trans, does the rear output bearing's snap-ring seat fully against the back of the housing? Or is it sticking out a bit?
If I remember, the ring should seat fully up against the body of the trans.

Other than that, if you did not change the output shaft itself, something may have become lodged inside the intermediate shaft in the adapter housing. Or that shaft is not seated fully in it's bearing. Or it shifted inside the adapter housing. Or something.

Guess you gotta' keep digging.

Paul

 

[needabronco]

Finally done. Now for the fun part...

OK I finally had success tonight. I took it all apart one last time, cleaned everything up (again), and it almost fell together. Now I've got everything sitting on the bench full of oil to double check for oil leaks. Now for the fun part, I get to wrestle the whole thing back in this weekend. Any body want to come help?

 

[DirtDonk]

Congrats! Lucky for me you're too far away to just pop on over. Phew! Got out of that cleanly.

Looks good all painted up and purty like that. I installed mine as an assembly just once. After that I always did them in separate pieces.
Floor jacks and one person calls for smaller pieces to lift and balance.

Good luck.

Paul

 

[needabronco]

My neighbor has a motorcycle jack that kind of cradles the assembly, well see how it goes...

 

[70_Steve]

I've pulled and replaced my 3-speed/Dana 20 combo a couple times as an assy. I have a 4x4 cut in sort of a V in the middle to set underneath the adapter, then set that on the cup of my floor jack. When it's up in the air, it actually balances pretty nicely. But I'm always concious of it falling, and I have a couple thick furnature pads on either side, just in case.

 

[needabronco]

I have a few pieces of 4x4 laying around I think I'll try that. Using the motorcycle jack works pretty well if I jack it up and let the d20 hang off the end, that way the crossmember lines up, but it can be interesting getting it under the body with everything balance in place.

 

[feitctaj]

the roller jack and a cut 4x is the only way, I rented a tranny jack and pushed it aside after giving the neighbors a Truck driver lingo lesson and slid my roller back under and it was much easier%)