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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: 06 Oct. 2021 at 2:50pm
Baby steps eventually get you there!

I was impressed with the "easy fill" hole on the rear cover that Bob W posted.  Thinking of welding one on to a spare cover.  With the open bearing and pass though holes I could take care of the tranny and t-case levels through just one easy to reach fill hole.

I really like that your gear does not protrude all the way through to the outside of the case.  Seems like a simple flat cover would work fine.  Really doubt that a heavy welded on cover is necessary for structural strength - just need to keep the gear lube from coming out.  You could even attach it with some small machine screws tapped into the case if the JB Weld didn't quite hold it.

Not sure what "extra long bolt" hole you would have to drill.  If it's the one that goes through the ear by the slot you cut, just using a socket head bolt should work fine.  That's what I did although I had to grind the edge of the bolt head a little narrower to clear the cover I welded on.  With a flat sheet metal cover you'll probably have plenty of clearance.

-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
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Stev View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 06 Oct. 2021 at 5:11pm
I liked Bob W. easy fill Idea, but that will not work on this transfer case because the PTO will be installed in that location. 

I will take a look at you thread and to see how you did the socket head bolt.  

Thanks!
Stev
1946 CJ2A Trail Jeep (The Saint), 1948 CJ2A Lefty Restored
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jpet Quote  Post ReplyReply Direct Link To This Post Posted: 06 Oct. 2021 at 5:51pm
If anyone is interested, this is what I did:



This is a long bolt, that I turned the head down on. The hose for my oil pump fits over the end of it. There is a hole drilled through the bolt which is tapped on the end and has a set screw. When I want to fill the case, I remove the set screw and slide the pump hose over the bolt head. Then I remove the next lower bolt for the cover and use that hole for fluid level.

Clearance:

These gears are big and there is not much room to work with, that being said, when the opportunity is there to add clearance, I would do so.   Obviously the idea is not to break a tooth but it does happen. Even the stock gears can chip a piece off. Hopefully, the piece will fall to the bottom and get stuck to the magnetic drain but if a piece comes loose and gets wedged between the gear and the case, it might do severe damage and take several teeth out before it clears. I have broken off teeth in my original gear set and my Rockeater set. Both times, only a portion of the tooth, or teeth broke off,
not the whole tooth. I was still able to drive back to the shop,

Edited by jpet - 06 Oct. 2021 at 5:57pm
CJ2A #29110 "General Willys"
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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: 06 Oct. 2021 at 6:03pm
Socket head bolt over the intermediate gear cover.

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
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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: 06 Oct. 2021 at 6:40pm
Very clever fill idea Jeff!
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
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 07 Oct. 2021 at 9:28am
Jeff and Barry - very helpful.

More clearance is better.  More Coffee...a lot more coffee.

Going to have to go with the long bolt option like Jpet did on his large hole case which involve the bolt passing through 3 holes in the case.

The bolt will need to pass through new hole #1 in the back wall of the case.  Then through new hole #2 in the center of the case and then through  existing  hole #3 that exists in the mounting flange to the transmission.

Need to figure out how to drill the two holes (#1 and #2) additional hole straight through the case and get it lined up with existing flange hole (#3) that mounts to the transmission.   Those two holes pose different challenges when drilling them.  I can mill a flat and use the existing flange hole to get a long drill bit to align hole (#2) in the center of the case in the "correct" location.   Hole #3 in the outer case wall will be interesting.   


Edited by Stev - 07 Oct. 2021 at 9:31am
Stev
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jpet Quote  Post ReplyReply Direct Link To This Post Posted: 07 Oct. 2021 at 10:00am
If you feel like mailing the case to me, I’ll put the hole in
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jpet Quote  Post ReplyReply Direct Link To This Post Posted: 07 Oct. 2021 at 10:03am
What I did was:

1. drill a hole in a flat steel plate same size as the TC hole
2. Stick a dowel pin in the hole
3. Set the case face down with the mounting hole over the dowel pin
This ensures that the mill spindle is in line with the mounting hole
4. Plunge down with a flat mill to make a flat surface in the TC housing,
5. Center drill and drill hole thru.
CJ2A #29110 "General Willys"
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 07 Oct. 2021 at 10:27am
Once again very helpful.  I will see if I can do that here - if not I will send it to you.  Thanks!
Stev
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 11 Oct. 2021 at 1:01pm

Thanks - collating the holes using the stud worked!


Edited by Stev - 11 Oct. 2021 at 1:04pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 01 Nov. 2021 at 4:22pm
Update:  The gear cover has been fabricated out of a section on 3/16 thick steel.  Ron has the case and is going to TIG Weld on the  patch like he did for Barry.  It is Good to have Willys guys with actual skills.  
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 05 Nov. 2021 at 9:49am

Super excited to get this patch welded on the case.  Thanks Ron!


Edited by Stev - 05 Nov. 2021 at 9:50am
Stev
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 06 Dec. 2021 at 8:26am
Rebuilt a T90A this weekend to go in front of the Lower Gears transfer case.  It is amazing the things that I don't have on hand or cant find when doing projects.  This time it was the steel transmission mounting plate that bolts to the bottom of the T90 case.  Had to order one from eBay.




Edited by Stev - 07 Dec. 2021 at 9:53am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 07 Dec. 2021 at 8:20am
Glad to see you're making some progress.  My Jeep projects have been at a stand still - the holidays and other commitments have taken priority.  I haven't even written my letter to Santa yet!

-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
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 22 Dec. 2021 at 8:44am




Stev
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 27 Dec. 2021 at 5:22pm
Installed a new transfer case pilot bushing, reamed it to .627 and discovered that the output clutch is bad.  It is .622 with some groves.  Ordered a new shaft.
Stev
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 19 Jan. 2022 at 5:05pm
Update - I am slammed with non Jeep work and commitments. -Helping to running the business, nursing home visits (4 hours away on the weekends), wiring the farm house, Covid care, racking up the wife points up.  Life is good!  But the Jeep transmission/ transfer case build is going slow because of it.

- Did finish up the 4wd shift assembly.  The output shaft did come in.
Stev
1946 CJ2A Trail Jeep (The Saint), 1948 CJ2A Lefty Restored
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 19 Jan. 2022 at 5:59pm
At least your making some progress!  Baby steps - you'll get there!

-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
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