G503 Military Vehicle Message Forums

Have your flywheel resurfaced and it will be fine.
You can ask your machine shop also, small heat cracks are usually not a problem even after resurfacing.


Ed

Making more progress. Got the flywheel resurfaced, new bearing installed and new 97 tooth ring gear installed. The small cracks are still there, but the machinist insists they are in tolerance and safe. Figure I will post pictures anyway for your opnion:

Looks just like my original GPW flywheel after machining.
Should give good service!

Ed

Some prgress being made over the Christmas break. I took a few days off for vacation and am really making a push to get a lot done. Focusing on the transmission and transfer case to get them back in the jeep, so spending a lot of time with Stirstick. He does such great work and is very meticulous.

Had to spend some money unexpectedly. Once the transfer case was apart, discovered one of the bearings was collapsing and beginning to swarm. Got a sone shavings in the cups and gouged the 3/4 inch cluster gear.

See the pits in the surface from the bearing pieces:





Didn't get a picture of the cluster gear but it had to be replaced.

Various parts:



The brake drum for the external early emergency brake was shot. See how it is bowed:



The new one for comparison:




The band was also shot:






You can see how the previous rebuilder painted the INSIDE of the case (don't understand that, it will only lead to paint flaking off later on):





The transfer case after bead blasting:







The transmission waiting to assemble:

Is the interior paint or "glyptol". It is pretty common practice to coat the inside of these type casting. Did mine several years ago, no flaking.

Dan

I might have to get you and Stir Stick to help me when I redo my Transmission & Transfer Case. They're not in as bad of shape as yours, but I want them "like New!"

Thanks for keeping us updated.

My original Ford trans and transfer case both have inside glyptol coating .
My NOS Willys transfer has it also.

Ed

The paint inside the case helps seal any possible casting porosity, which is actually a fairly common problem.

Make sure that the input shaft of the T84 is a slip fit in the pilot bushing in the flywheel, they sometimes shrink the ID when you press them into the flywheel. A reamer can be used to open it up if it's too tight, just don't use a brake cylinder hone, the grit from the hone will get imbedded into the bushing, which will grind the pilot tip of the input shaft.

Howdy,
The inside of Rodneys transfer case was primed with something besides Glyptol . This paint would come off on a towel with mineral spirits on it . It is also soft and would come off under your finger nail . The pilot bushing will also be checked and reamed if needed . The cage bearings had come apart and wiped out the inside of the intermediate gear , and shaft . Metal flakes were evident in the cone and cups on both ends of the output shaft . The case's will be washed out , and blown out with air before assembly . The end play on the intermediate shaft will be set correctly with a dial indicator . Rodneys transmission and transfer will be suitable for an every day driver . . Keep Em running !
Stick

Hey Rodney
Im enjoying watching your project good luck with it.
regards Nick

Wow...amazing work Rodney.

Please, keep showing your work!!

Thanks Nick and Rodrigo!

I must say that I must give Stir-Stick the credit for the transmission and transfer case part of the project. He has been a blessing on this effort. His work is absolute first rate.

Another issue with the Transfer Case. Looks like Bubba didn't realize there was a shoulder built into the Front Output Housing to hold the bearing seal in.
Thankfully, Stick happened to have an extra Front Output Housing so it doesn't hold us up. I need to procure another one so I can get Stick one back. Anyhow, looks like Bubba banged on the shoulder instead of the bearing and hit it so hard he sheared it off.

The original without the shoulder



The replacement with the shoulder



The original without the shoulder



The replacement with the shoulder

Wow, you dodged a bullet having a housing handy for replacement to not slow you down.

Your project is looking great, Rodney.

Keep up the good work!

Making some progress this week. Hoping to re-install the clutch, bellhousing, transmission and transfer case in the next day or two Lord willing.
Until then, I was able to remove the incorrect webbing that Bubba installed and also get the Bellcrank ready for replacement.

On a different note, are my headlight brackets installed incorrectly onto the grill?

Webbing before







Webbing After







Bellcrank








New Bellcrank parts