Big Blue's Transformation

[salans7]

Gary Lewis wrote

I can take a pic of another column, if that's what you mean.  Oh, maybe take a pic of an automatic column's lower bearing retainer and then the same pic of a lower bearing retainer for a manual tranny's column.  Is that what you mean?

I just need to see the bottom of the housing where the bearing retainer goes on a manual column. I have my auto column fully assembled so no need for auto column pics. I think I can get by with just a small sheet steel patch and some sealer, but I want to be sure that's sufficient. Scott's pics lead me to believe so, but his pictures don't seem to show the completed column in that area.

[kramttocs]

Looking at your first photo in the steering post, it looks flat and flush to me. Interested in what you find.

[Gary Lewis]

Ok, here's what I found.  Pics to follow.  Measurements on my two rings and bearing retainers, with #1 being the ones I'm using.  And I'm going to run it this way.

Red Ring OD:
#1: 1.175-1.177"
#2: 1.182-1.190"

Bearing Retainer ID:
#1: 1.167-1.170"
#2: 1.160-1.162"

Obviously #1 ring in #1 retainer is a tight fit, but it works nicely - as you'll see.  #2 ring in #1 retainer fits, but one edge creeps up slightly.  In either case, they effectively seal the entrance of crud into the bearing, and when you turn things by hand there's a slight drag.  But I'm sure the drag will never be felt when you are turning the wheel.

Here's an overall view of how the ring fits in the retainer:




And here's the other side, showing it locked in nicely.  Scott - yours didn't lock in as it wasn't down in the bearing retainer.  If you think about it, if it can lock in one way it'll lock in the other.

[Gary Lewis]

Shaun - What other pics or measurements do you need?

[kramttocs]

<quote author="Gary Lewis">
  Scott - yours didn't lock in as it wasn't down in the bearing retainer.  If you think about it, if it can lock in one way it'll lock in the other.
</quote
Yeah, if yours fits down in the retainer so it's up against the bearing and can latch, I'd run it that way. I cleaned both surfaces of mine but it won't fit.

[Gary Lewis]

Do you want my #2, no pun intended, red ring?  Is it smaller than yours?  Maybe it would fit down in your bearing retainer?  It sure looks like it'll be a good seal.

And now onto a question and a comment.

The question: Does anyone know where the wires are supposed to come through the pedal box?  Or are they?  I'm struggling to find a way for the wires to get to the brake and clutch pedals as well as the ignition switch.  I thought there would be illustrations in the documentation showing the wiring but I can't find it.




Also, I think I found another use for seam sealer - the steering column boot.  Here's a test fit, and if you look closely you can see two pieces of metal in the firewall.  But what you can't see is that there's a third - the firewall brace.  And this boot only fits up against the brace, which will allow water to come into the cab between the brace and the firewall.

So I'm thinking I'll goo the boot with seam sealer before installing it, and then smooth over the sealer on the engine side of the firewall to seal the boot to the firewall.

Anyone have better ideas?

[kramttocs]

Gary Lewis wrote

Do you want my #2, no pun intended, red ring?  Is it smaller than yours?  Maybe it would fit down in your bearing retainer?  It sure looks like it'll be a good seal.

Appreciate that - sounds like a great parking lot mini-project for the end of September

Seam sealer sounds like a great fit for that purpose.

[Gary Lewis]

Yes, it could be a mini-project.  Pull the intermediate shaft, pull the 3 screws, and wiggle the retainer out.
 Can Campbell help?  

And, on the seam sealer, the struggle will be to keep it off of everything else as I stab the steering column in.  The problem is that rat's nest of wires that are intended to go below the steering column and aren't long enough to go above.  I either need to tape it together or put convolute over it , at least while installing the column since right now it goes everywhere.  Or, maybe I should lengthen and re-route the wires like they should have been done originally?

But, I did find the clutch start switch connector and pulled the jumper that was in it and connected it to the start switch.  So now it shouldn't start in gear.

However, the question about where the other wires go was finally answered - not through the pedal box.  I'm pretty sure of that since they aren't long enough to make that happen.  So, I've loosened the pedal box and am trying to snake the wires out.  However, it looks like I'll have to pull the brake master and let the front of the box drop in order to get the wires out.

Must remember that two steps forward and one back is still progress.  

[kramttocs]

I am sure she will be there this year again to lend a hand

What about applying a bead of the sealer on the inside of the firewall instead of on the column? Or really even applying it from the engine side and working it in would work also.

I have some photos of how the wiring went in that area before the tear down on my truck and could take some now but not sure if they are what you need as it sounds like yours are quite a bit different? Mine are all above but yours are intended to go below? Sorry, I don't think I am up to speed with all your wiring changes.

[salans7]

When I pulled the pedal assembly from the parts truck in the junkyard, I remember the wiring for the ignition switch and turn signals being intertwined in the pedal assembly. I could not remove the pedal assembly without unplugging those connections, which tells me those wires went through the pedal assembly.

[Gary Lewis]

Scott - Glad to see she'll be here.  Tell her the roller coaster will be out.  And bring the whole family, please.

As for the wiring, pictures would be helpful.  We are going into Tulsa tomorrow so I won't get to it until Friday.

And I like the idea of a bead of seam sealer on the firewall, inside, that will go through with the boot.

Shaun - I was remembering that as well, but it isn't working.

I'm not making any wiring change in that area at the moment, so this is stock wiring.  I'm confused.  

[kramttocs]

Just got home so going to look for some videos/photos. Did take a quick under the dash video but it's not the greatest.

The large conduit covered section of wire that comes from the left goes over bracket (up near the bottom of the cowl) and comes down through the hole in the top. From here the ignition circuit hooks up on the top of the column along with some other connectors like the turn signal. It then goes under the bracket on the right side and continues on. From the right side the cruise control vacuum hose comes in through the hole on the right side, makes an upside down U and hooks into the dump valve.

This was on the automatic but I looked at the 85 manual and it was the same.

What is the conduit covered long length of wire going horizontal beneath the whole assembly in your photo? I don't recognize it.

[Gary Lewis]

Scott - Thanks.  What you described in text as well as showed on the video is how I remember it.  So I have something wrong with the earlier part of that large section of wiring, like maybe it is caught on something, as it won't come through the hole far enough.

That's enough for me to go on, and it helps a bunch as it means I probably don't need to pull the pedal bracket off.  I have it loose so it drops down a bit, but it is still attached to the brake booster and to the dash loosely.  That lets me move it around to get clearance for the wires so I can move them.

As said, we are headed into T-town tomorrow and I'll not be back on this until Friday, but hopefully can get it all connected up and the steering column installed then.

[kramttocs]

Glad that helped and that it won't require much disassembly to get back on track. It being caught on something makes sense.

Enjoy your trip!

[Gary Lewis]

Guys - As I'm sitting in Barnes & Noble thinking about things I've come to a conclusion I want to bounce off of you.  And that conclusion is that I want to break Big Blue's Transformation into two phases:

Phase 1: New carbureted 460, ZF5, D60 SAS, yada, yada, yada

Phase 2: EFI for the engine, upgraded fuel system, etc

The reasoning for this is to get Big Blue back on the road and to enjoy him a bit before launching into the next phase, which will be over the next winter.

I think the downside is that there are a few things I'll do that will have to be undone, like installation of the seat and carpet - which may have to come out if I put the ECU under the seat.  And the aux battery, which may have to be relocated when the EFI goes in due to all the things that will be lined up along the driver's fender.  And, I'll have to buy a carb adapter for the EFI lower plenum.  But, for the most part I don't think there will be all that much re-work.

What are your thoughts?  What am I missing that might be big gotchas?

[kramttocs]

Gary Lewis wrote

 What am I missing that might be big gotchas?

Too much enjoyment driving it that you won't want to take it down again?

[Gary Lewis]

Perhaps!  But it'll be fun either way.  

[ArdWrknTrk]

You know, before I had to give away the 450's excellent running engine (and Y-piped non-catalyst exhaust) I was sorely tempted to just throw a Price Motorsport adapter plate and my 750 Holley on it and drop it in 'Lil Red.

[1986F150Six]

Gary Lewis wrote

What are your thoughts?  What am I missing that might be big gotchas?

Two phases is a good idea! Babies crawl and then walk!

[Ford F834]

+1 on the two phase approach. The little bit of back tracking you will have to do is not that bad, and worth it in my opinion. Not only will you be able to enjoy the truck this year during the nice weather, but it will give you the chance to test and work the bugs out of phase 1 before taking on phase 2. That is the problem with changing/rebuilding many things at once, you have test and fine tune several things at once. If it were me, I’d want the new engine and driveline swap stuff all tested, tried and true, before throwing the EFI electrical and fuel delivery aspect at it. Maybe it’s my loathing of multitasking, but that’s how I would want to approach it.