Topar's build

[topar]

Oh & my buddy Zack junked the brown truck above & is in the process of building a 79 long bed.  It looks good so far.

[topar]

I almost forgot the person in charge of this truck.  My son Cole Monster!  He is 4 now.

[topar]

I had about an hour to kill today after Dr. appt. & time to get ready for work so I got a little more work done.  Intermediate shaft removed as well as rear gears.





The parts box's are getting bigger.

[topar]

About 30 min of work today & I got:





The rear shift rail removed as well as:







The front output housing removed.  One day I might get this thing done! 

[topar]

Picking up a bearing separator & gear puller tomorrow.  Hopefully be done with tearing down the T case Wednesday or Thursday.  Then start cleaning it up remove the pills & do a little grinding & welding put it back together.  If all goes well I will hopefully have enough cash left to start a hydro assist. steering setup.     In case I did not say before this is a Dana 20 case.  My truck is defiantly a jack of all parts Toyota, Chevy, Jeep & homemade parts all in one.   

[topar]

I have gotten some work done since my last post:





Case is empty now.

[topar]

I cleaned it up last night, then prepped it for paint tonight:

[topar]

Started painting it tonight smurf blue to match the truck of course:

[topar]

Now I just have to wait for some springs to come in that I ordered last night, then remove the pills from the front out housing & a very small amount of welding - grinding & I will have a twin stick Dana 20 for less than $50. 

[topar]

Still waiting on my parts.  Did I tell you guys I am not a patient person?

[topar]

Small bag of parts came in finally 



Custom tools for putting bearings back on:

[topar]

Started reassembly:

[topar]

Reassembly:

[topar]

And that's as far as I got till the wife came down to remind me that her & Cole had gone to bed & that hammering sure does make allot of noise.   

[AaronB]

good to see you back on it, wish I had the time for mine.

[topar]

Thanks, hope your family is doing well!  Wish I knew what I was doing since like a dummy I put the bearing on the wrong end of the shaft so back out came the bearing puller.   



Then put it back on correctly.

[topar]

Putting the front output shaft in.

[topar]

Rear cover front output.



Now finishing the front side of the front output shaft.

[topar]

Custom tool, okay its a sink drain pipe & a piece of flat stock held together with duct tape but hay it worked.   



Done.

[topar]

So then I put the spring in & the detente ball for the front shaft & placed the front out housing on.



Front output on.

[topar]

Holes where the springs & detente balls go.



Placing the spring & detente ball in for the rear shift rail (man its a pain holding the spring & ball down while trying to get the shift rail in).



Got them in & covers on.

[topar]

Unthinkable is starting I will finishing posting when its over been wanting to see this movie.

[topar]

Paused the movie popping some popcorn.



Covers on the detente balls.

[topar]

See that's what happens when you get distracted, you post the same picture twice.   

[topar]

Starting on the intermediate gears.  You have to place all the needle bearings & 3 washers all through the inside of the intermediate gear.  I used Vaseline to hold them in place.

[topar]

Or I could show you the same picture 3 times, just to make sure that everybody understands that the covers are orange      Okay now for the right picture:

[topar]

Intermdeate gears & shaft in place.  I am starting to feel like I am doing okay.

[topar]

Gave the intermediate shaft one last hit to make sure it was seated all the way in and I break off the peace that holds the lock in place.   

[topar]

Bad news is I have to take it back apart, good news is I have another case with chipped gears so I can use that shaft.  I just have to be very carfull on the next one.     I wont be working on this for a few more days though.  I am working Wednesday - Friday night.  Maybe work on it down at our shops (So I wont have to be so worried about being loud ) Saturday or Sunday night.

[topar]

Went down to Lowes & bought a shower rod which I cut down & used to get the broken intermediate shaft out without knocking out all the needle bearings, & made a another custom tool.



It worked as planed.