Big Blue's Transformation

[Gary Lewis]

Good point.  Having several spare crossmembers of at least two different styles, I might have the parts w/which to do that.  And, if Ford kept the same cross-section they might fit together nicely.  But, this is the same Ford that changed the spacing on the transmission mount after decades of the wider spacing working well, so....

Headed out to run some errands in a bit, and hope to play with the new scanner when I get back, but also plan to put the t-case in place and find out how much interference there is.  And then, with spare crossmembers already laying on the floor it'll be easy to see what I can make of them.

[Nothing Special]

Gary Lewis wrote

....  My thinking is that right now is almost the worst possible interference.  The truck is on the lift with almost the max suspension drop.  The previous test shows that the shocks will let the front axle go down another 2" or so, but I think that would only happen in a situation where the axle is dropping rapidly, like in a jump.  Otherwise the springs should stop the travel where it is.  Right, guys?

Right, but...

There's enough unsprung weight = inertia in a Dana 60 that I wouldn't count on the springs limiting the travel there.  There will be some dynamic effects even in much less violent maneuvers than a jump.  Will the axle regularly make all the way to the shocks limit?  Hopefully not (if so you might want to consider limit straps to protect your shocks and shock mounts).  But if the driveshaft is just barely clearing the cross member as it hangs now I'd be concerned that it wouldn't always clear.

[Gary Lewis]

Bob - You are right that the D60 is HEAVY (I've carried the "light" end four times now) and it'll continue to move.  Or, maybe more correctly, isn't going to move until the shocks get to the end of their travel.  So I can't just get enough clearance for where it sits.  It needs more.

I put the t-case in place, which is all the lift this old man wants to attempt, and then put the double-cardan shaft in place.  And, it is official that it hits.  Pics below, but it looks to me like it is about 1" too high.

I'm going to put the tranny jack back under and remove the crossmember & gussets.  I have another crossmember that has a ~2" drop that I'll try and see if it works.  Will post after a bit of testing....

[1986F150Six]

Engineering at its finest. You will figure it out, Gary!

[Gary Lewis]

Thanks, David.  I may have it figured out.  I installed the crossmember, shown below, that has the ~2" drop and I think it'll work.  But want y'all's input on two questions:

  1: The clearance - is it adequate?

  2: The gussets - can I use the ones that are in w/o drilling new holes?

The clearance measures just over 1/2" with the suspension drooped as far as it wants to go, like on the lift.  But the shocks will let it go another 2" if it wants to.  However, the math says that 1/2" of movement there would allow over 3 1/2" of travel at the wheels since the pinch point is 6 1/2" from the pivot and the axle is 48" from the pivot.  I think that's adequate.  Youse guys?

As for the gussets, the ones that go with that crossmember will bolt up with it ~1" back, meaning using the new holes, which is where it needs to be.  But the front edge of each gusset is ~1/4" below the frame before tightening the bolts up.  However, it will go up to the frame before reaching the torque limit of 85 ft-lb of the 10.9 12x1.75 fasteners.  I think that's a better way to go than to drill two new holes on each side, which reduces the strength of the frame.  Y'all?

Here's the right gusset's gap before tightening it up to the frame:



Here's a shot of everything in:




And here are two shots of the clearance.  Why two?  Because the one on the left is the least clearance (11/32") and the one on the right is the most (11/16").  That's because the double-cardan joint is smaller than the output yoke of the BW1345 and I was only able to get one screw in to hold the shaft to the yoke.  That puts the joint off center.  So I measured the most and least clearance and averaged it to get 17/64". , meaning just over 1/2".  (Truth in posting.  )

[Nothing Special]

Gary Lewis wrote

....
  1: The clearance - is it adequate?

  2: The gussets - can I use the ones that are in w/o drilling new holes?
....

Both seem good to me

[salans7]

What is the clearance between the transfer case and the floor of Big Blue? That ZF5 crossmember sits lower than any other crossmember for a reason. I know the E4OD brought you some issues with the floor on Dad's truck.

[Gary Lewis]

Bob - Thanks.  I agree, and I've now drilled the hole out on the driver's side bottom and installed/tightened all the fasteners.  It is now truly IN.

Shaun - I can just get the palm of my hand between the t-case and the cab.  So I'd say there's about an inch there.  Lots more than on Dad's truck.

On a slightly different topic, I had to stretch the F350's front driveshaft to get it to fit into the yokes.  Turns out the boot was what was pulling it back in.  So I cut the band off and that allowed it to slide in and out nicely.  And the splines look very good.

There were about 2" of splines sticking out with the suspension drooped, but I need to check to see that there are still splines engaged if the axle drops the other 2".  And, I need to see that the splines don't bottom at full compression.

If all that checks out I need to order in the u-joints and rebuild the shaft.

[salans7]

  

[ArdWrknTrk]

Progress is good!  

[Gary Lewis]

Siskel and Ebert only gave two thumbs up, so I'll assume that three means "perfection".  

Boy, is it a RELIEF to have that sorted.  Now I can move on.

[Gary Lewis]

Yes, Jim, it sure is!  Thanks.

[Frank Wyatt]

I've been following along and while I don't have anything to contribute to the project, I can say that you are doing great work. Your projects have inspired me to get started here a while back sorting things out on my truck that had been over due for correcting. Taking a break on my truck right now for better weather as I have the mechanical and safety related issues taken care of. I don't care for laying in the driveway in the wet and cold. It would not be so bad if I could at least get it in the car port, it's closed in on three sides.

[Gary Lewis]

Thanks, Frank.  I'm glad it is helping to inspire you.  That is one of the many advantages to the forum - seeing what others are doing inspires us to get going ourselves.

[Frank Wyatt]

Plus seeing how others are doing things often results in ideas on how to do some things differently. For example cleaning up the wiring by installing a PDC box under the hood for the fuses and relays of added on accessorys.

[ArdWrknTrk]

I still have to get on this.

Maybe while I'm down in Swarthmore helping my sister convalese, I'll put the time in.

[Gary Lewis]

Sounds good, Jim.

Swarthmore - makes me think of Momma Cass.

[Nothing Special]

But she changed her mind one day.

[Gary Lewis]

Nothing Special wrote

But she changed her mind one day.

Yep, according to Creeque Alley:

When Cass was a sophomore, planned to go to Swarthmore
But she changed her mind one day

[Gary Lewis]

As for what I'm into now, it is time for the t-case rebuild.  Here's what the workstation looks like, with:

New parts, meaning gaskets, seals, bearings, and double-cardon front yoke on the left

Dirty BW1345 in the middle

Special Tool: That's a 1 1/4" socket on top, which is the size of the nuts on the output shafts.  However, that thing measured 1.730" OD and the recess in the yokes measures 1.670" ID and .900 deep.  So he took a few spins in the lathe and came out measuring 1.650" on the last 1.0".

IPad: Got to thinking that I'll want to be following the either the FSM's or Borg-Warner's instructions, both of which we have on the Transfer Case page, but I don't want to have to come back to the computer for each step.  Then it dawned on me that we have an OLD iPad that we initially set up for the g-kids, replete with a pretty serious rubber case.  But, it is sooooo old and slooooow that no one wanted to use it.  

So, now to get dirtier!  (Got dirty just carrying the thing in.  )