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Barrys Builds

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Barry S View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 04 Oct. 2021 at 9:35pm
More progress tonight.  I replaced the worn and sloppy rivets holding the forks onto the shafts in the shift tower with hardened spring steel roll pins.  I used 3/16" x 1" roll pins.  It took out all the slop.  I test fitted the tower onto the tranny and 2nd gear fully engaged.  Yay! 

Tomorrow is test drive day! 

The old rivets are standing up at the bottom of the photo.

1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 05 Oct. 2021 at 8:55pm
On the road again.....!!!!!! Clap

Tonight I buttoned up the floor panels, ran it off the blocks and took Grasshopper for a spin.  Ran beautiful!!  No noise or problems - all gears and ranges shifted smooth and solid.  Maybe it's my imagination but the tranny and transfer case seem quieter and more solid than before.  Down shifted hard into 2nd gear several times - no pop out!!  Transmission work paid off!  Low range feels like a snails pace and the gears are quiet.  The only heart stopper was when I first pulled it out of the barn and when I pushed the clutch in, the Jeep stopped quickly like something was binding.  Then I realized I still had the parking brake on.  Whew! - that was a relief.

I took a picture of the odometer to remind me to change the tranny and t-case oil at 100 miles.


The new lower gears really make a big difference in the low range travel speed.  Before I started the t-case swap I set an orange cone in the driveway (cone on the left in the photo), put Grasshopper in low range first gear and let him idle.  When the front bumper passed the cone I started timing 30 seconds with a stop watch.  After 30 seconds had elapsed I stopped and placed the second orange cone even with the front bumper, 66.5 ft. (Cone on the right in the photo).

Tonight, after swapping in the t-case with Jeff's gears, I repeated the test.  Grasshopper is sitting where 30 seconds had elapsed,25.5 ft. About 1/3 the distance!  I think I'm going to really like the new gears for rocks and ledges!


In the coming days I plan to do some other little fun tests of the new gears.  This Sunday I'm planning to attend the Geauga Jeep Invasion.  It's a nice country ride through the Chardon and Middlefield areas that will give me a chance to put some miles on the new gears in high range.  Then the following weekend is the Ohio Fall Colors ride that will let me put Jeff's new low range gears through their paces.

Thanks jpet!!

-Barry


Edited by Barry S - 08 Oct. 2021 at 7:53pm
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jpet Quote  Post ReplyReply Direct Link To This Post Posted: 05 Oct. 2021 at 9:20pm
Glad to hear it. Maybe text me a slow crawl video when you get a chance and I’ll add it to the others.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 09 Oct. 2021 at 6:35am
Grasshopper crawls with jpet's gears.

1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote JeepFever Quote  Post ReplyReply Direct Link To This Post Posted: 09 Oct. 2021 at 10:45pm
Smooth!   Smile
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spangenwerks Quote  Post ReplyReply Direct Link To This Post Posted: 11 Oct. 2021 at 7:45am
This weekend lets do a turtle race! 
Ron Spangenberg
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Post Options Post Options   Thanks (1) Thanks(1)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 11 Oct. 2021 at 9:41pm
Yesterday we took Grasshopper to the Geauga Jeep Invasion for a nice fall ride.  There were about 180 Jeeps in attendance and goal was to raise $10,000 for Geauga County veterans.  I counted 16 flat fenders with 10 being military.


Beginning of the ride.


The route took us past East Branch Reservoir and through 2 covered bridges on the Maple Highlands Bike Trail.



Finally we drove under a salute to our veterans set up by the local Fire departments.


It was a very nice way to spend a morning - supporting our vets and hanging out with a lot of other Jeep nuts.  I've got 30 miles on the new gears now, all high range - transmission and transfer case performed beautifully.  Next weekend will be lots of low range on the Ohio Fall Colors Ride.
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote TateC Quote  Post ReplyReply Direct Link To This Post Posted: 12 Oct. 2021 at 1:17am
Looks like a fun ride! Thanks for sharing 
Tate Christensen
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mbullism Quote  Post ReplyReply Direct Link To This Post Posted: 12 Oct. 2021 at 6:48am
solid shakedown, and for a good cause Thumbs Up
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 18 Oct. 2021 at 12:55pm
Barry - did you ever figure out the clicking noise coming from the drive train?  I did notice that the front output shaft (Dana 18 transfer case) had some play compared to the rear put shaft when if shook it.  Maybe it is the way it is suppose to be.  Just something to check. 

Edited by Stev - 18 Oct. 2021 at 12:56pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spangenwerks Quote  Post ReplyReply Direct Link To This Post Posted: 19 Oct. 2021 at 8:29am
Ive been thinking. Smoky in here. Barry, you dont have hills in madison except for logs and ramps and such, its possible this issue is external, in your drivetrain that didn't reveal itself til you got into hills and is more pronounced since the xfer case is now solid. 
Another clue is that when I drove it I noticed that drivetrain "growl", not present in mine, that goes away when motion and drivetrain are at equalibrium, indicating movement in a shaft or thrust bearing, diffs perhaps? 
Ron Spangenberg
51 CJ3A- L134, D18, Disc Brakes, rear lockrites
47 CJ2A, original, unrestored
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 29 Oct. 2021 at 8:22am
A lot has gone on in the last few weeks and as usual I am playing catch up on posting.

First, in response to Bob and Ron's questions - the source of the clicking noise we were hearing on the Ohio Fall Colors Ride is in the transfer case.  Jeff's gears are fine - the noise is coming from the slide gear which seems to have a bad tooth.  I had purchased the gear used.  Now I get to rebuild it again.  On the bright side, I'm getting lots of practice!  I will post more on that later.

Prior to the Fall Colors Ride the 2 biggest projects were putting a larger winch on Grasshopper and making a top of some kind for Ron's CJ3A.  Both projects were pushed because of the potential for lots of rain.

A PO had installed a 2000 lb winch under the "porch" on Grasshopper with the cable coming out thru the bumper.  I liked that it was hidden but it was way undersized and you had to reverse the wiring under the hood to change the winch direction.  I replaced it with this 12000 lb remote control winch.  I don't really care for the look but it will probably pull anything I ever throw at it.  Eventually I'd like to move it back down and have the hawse thru the bumper, but for now I'm going to make a canvas cover to hide it.


Ron bent and welded his own bows.  They came out real nice.  He even made offsets to bring them to the outside of the tub.  He bought a canvas tarp from Tractor Supply.  We had to experiment to find the right size rope to fit into the windshield frame track.  Once we settled on the rope size, we made a 2" fold across the front edge of the canvas and sewed it forming a sleeve.  Then we pulled the rope thru, held it tight against the inside of the fold, and sewed another seam keeping the sewing machine foot tight against the rope.


Once the front was secured to the windshield Ron just marked and trimmed around the edges.


Eventually Ron will make sides and a back but since we were under the gun for the Fall Colors Ride, we just sewed on straps going back up to the front pull the top taught, and rolled the sides up around the horizontals.  That was enough to keep the rain off for this trip.


Here it is in the line up.  Love the color!

1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 29 Oct. 2021 at 9:12am
The Ohio Fall Colors Ride was awesome.  The rain quit just as we were getting started so Ron's new top didn't get put to much of a test and no one got stuck so I didn't get to try out the new winch.  You KNOW that had we not made those preparations it would have poured rain all day and we all would have needed to get pulled! 

Bob Evans, Ron, and me camped right at the meeting spot and got to try out my new fire pit.  I had them put the Jeep logo on and the Willys logo on the other side.  It kept us nice and toasty!


Here are a couple pics of me and Ron.  I posted the rest in "Shows and Get togethers" here:   https://www.thecj2apage.com/forums/ohio-fall-colors-ride-oct-16-2021_topic49178_page3.html


1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (1) Thanks(1)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 29 Oct. 2021 at 12:05pm
The Ohio Fall Colors Ride was the first real test of Jeff's gears.  They worked flawlessly. I was able to negotiate obstacles in a far more controlled manner.  With the stock 37:1 final drive ratio, when I would try to climb a rock or ledge I would have to bash into it and be racing the engine while slipping the clutch.  Rough on the jeep and the driver.  

With the new gears giving me a 77:1 final drive ratio I was able to idle right up to the obstacle and the jeep would crawl right up with just a little added skinny pedal - with out pushing the clutch in - no bashing - no engine racing - no smoking clutch - no driver clenching his teeth and wincing!  What a difference - love the new gears!

I did hear a noise that concerned me.  I noticed it at the beginning of the first trail that I needed to use low range.   The clicking noise is coming from the transfer case and is only present in low range and most predominant in 3rd gear.  

After returning home I jacked up the rear end of the jeep and turned the front locking hubs out.  That let me run the entire drive train except the front wheels while I very cautiously listened.  I didn't want to stick my head under the jeep with the rear wheels spinning.  I was able to confirm that the click was coming from the t-case.

Next I put the jeep up on the blocks, blocked all the wheels and disconnected both drive shafts.  Then I felt safe being under it with everything running.  I tried every combination to isolate the click and narrowed it down to the slide gear.  I then marked the exact spot on the gear where the click occurs and coated that area with dytel.  Here is a video with the engine running.


Here is a video of the click moving the gears by hand.  


Here are photos of the mesh pattern on the tooth in question.  Notice that the other teeth are meshing smooth across the faces but the one marked is only hitting on 2 little raised spots.



I tried filing the 2 high spots down with a small diamond file but it didn't make any difference on the click noise.  Next step was to pull the transfer case back out so I could work on it easier and replace the slide gear.  I have another used slide gear I could put in but I may try filing this on some more.

The most important thing is that Jeff's gears are perfect - dealing with a defective used slide gear is small potatoes in the big picture!  The plan is to pull this t-case and reinstall the old one for now so I can wheel with Seth in a couple weeks.  When I get the click out of this one I'll swap them again - getting lots of practice!

So I have pulled the t-case back out of the jeep which makes a third time using the transmission jack.  The tranny jack makes the job much easier and safer but because the transfer case sits on an angle, I struggle to keep it positioned on the plate of the jack.  The little legs that came with the jack are useless for this t-case and I've almost had it slip off the jack.  To that end I decided to make a cradle to hold the D-18 that would set flat on the jack plate and hold the t-case at the proper angle.  After a bunch of experimenting this is what I came up with.




The pan bolts rest on the edge of the plywood and hold the case at the proper angle.  The case still wants to slide down the incline so I just laid a wood shim inside the cradle that the oil drain flange sits on to stop the case from sliding.  All the mounting holes are accessible.  Now the the t-case sits nicely on the plate and the chain is just for safety.  I am thinking of putting a couple bolts down thru the cradle and plate - then I might not need the chain at all.

I searched for something like this on this site and on google and didn't find anything.  I'm planning on making a sketch of the cradle with measurements and sharing it here on the site but I'm not sure  what heading to put it under.  "General Discussion Area"?  


Edited by Barry S - 23 Nov. 2021 at 7:44pm
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bufordjeep Quote  Post ReplyReply Direct Link To This Post Posted: 29 Oct. 2021 at 6:15pm
Barry -  What a great solution.  Have struggled with keeping the TC on a flat plate trans jack.  Where ever you decide to post the dimensions there will a lot of us who appreciate it
Thank you!
BTW did you bolt the cradle to the jack plate?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 29 Oct. 2021 at 8:37pm
Just finished installing the old t-case back into Grasshopper.  The cradle made it sooo much easier.

Here's another picture with the door shim and a sketch with the dimensions.  I just hold the t-case where I want it on the slope and push the shim in until it bottoms out on the drain flange to hold it in position.  By having the t-case pan bolts rest on the cradle, it doesn't interfere with the brake lever and is not in the way of the mating faces on the t-case and tranny.  It also allows access to all 5 mounting bolts.  

I did not bolt the cradle to the jack plate - it worked just fine.  Sliding the cradle around on the jack plate let me make fine adjustments without moving the jack.  As long as the jack rolls easily I may try bolting it - I still have to use the jack 3 more times once I get the other T-case back together.

Hope this helps somebody!

-Barry




1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 31 Oct. 2021 at 9:10pm
I'm trying to get ready for a potentially cold 2 day run in PA in mid November.  There was a heater in Grasshopper that might come in handy.  With no top I never bothered with it - never wheel in the winter.  I tried it yesterday and of course, the fan motor wouldn't run.  I ended up pulling it out - no small feat - it seems like a nice heater - stainless steel.  After a motor rebuild, new switch, wiring and repairing an inline fuse holder, it works great.   With just a bikini top I'll be heating the great outdoors, but hey, maybe it'll keep my feet warm!



Today's project...
With the bikini top it seems like a lot of wind hits me in the back of the neck.  I decided to make a windjammer at Bob Evans suggestion.  Here's how it came out.


I ordered some footman loops from E Bay for the bed to finish it up but I'm happy with how it turned out.  My sewing skills are improving thanks to my wife's coaching.
  
So now with warm feet and no wind blowing down my neck, maybe I'll survive.  Now if I could just improvise some doors....Smile


1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Flatfender Ben Quote  Post ReplyReply Direct Link To This Post Posted: 31 Oct. 2021 at 9:25pm
That’s a great wind jammer!!
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