My 67 CJ5 build

So I read Rick Stivers article again on the T-90 rebuild and he ran into the same issue with the spacers not being flush with the ends of the countershaft, so as he recommends I added a washer to each side and It brought the washers pretty close to flush. As for the front countershaft washer here is a photo. I decided to get a new one after looking at the damage again.

 

While waiting for another thrust washer for transmission I assembled the transfer case. I followed Stivers directions as well as referencing a couple of other sites. So if these posts look familiar that's why

I laid out all the parts to get some organization

 

Started with speedometer gear




Nextt the bearing and snap ring


used a seal installer to seat the bearing

 

Output clutch shaft going in




Short shift shaft with fork


Output clutch gear


Installed with shift fork

 

I painted everything on the case then sanded the mating surfaces so I can see any high spots.





Long shifting shaft with fork





Used a deep socket to put on new bearing to output shaft

 

Sliding gear on the shift fork



output shaft gear



output shaft slid in



next the thrust washer with the tab inserted in the shaft groove that goes back thru the gear



Snap ring



washer and snap ring installed

 

Bearing installed



bearing cup



tapped the bearing cup flush, bearing cover will seat it the rest of the way



temporarily installed the front cap with gasket ( without sealer ) so I can set up end play on shaft

 

I read setting up the rear cap shims were a pain in the butt and they were



After many tries finally set the end play at 0.005



sprayed the shims with copper form a gasket



slipped on speedo gear



rear bearing cap installed

 

Removed front cap and installed seals



interlocking pin



pin shouldn't protrude. move shaft if it does



I used gasket shellac on all the gaskets



front cap installed

 

On to the intermediate shaft



I used a 1 1/4" wood dowel cut to 2 5/8" long to keep everything in place. Added first washer then 24 needle bearings, center washer then 24 more bearings, than last washer. I coated inside of shaft with assembly grease first





Applied thrust washers to case with assembly grease to stick them, then put a dowel in each side to hold them

 

Slid the gear into case and pushed in dowels a bit to hold it in place



removed the first dowel then slid in the shaft making sure I did not catch the edge of any of the needle bearings. If it works the shaft should push out the other dowels



shafts in



locking plate installed

 

I then added poppet balls and springs to the front cap, Before doing this the shifting shafts moved freely, after, I couldn't budge them. I hope that is right. I believe thats what they are designed to do, keep the shafts from moving to free





rear seal installed



oil pan gasket and sealer







Love making these things new again





Just have to blast and paint E-brake drum and backing plate and install.
Transmission next

 

I decided to get the drive shaft yoke blasted and painted, A coat of Por-15 and then some cast iron grey from Eastwood



Felt seal applied



Used an impact gun to tighten washer and nut



A reminder to me to torque the nut after case is mounted for leverage

 

First tool to buy to do a restoration ? Blast cabinet



Cracked E brake drum......more money

 

I got all the parts in for the transmission and got it rebuilt. I got the transfer case mated with the transmission again, took apart the shift housing and cleaned, sandblasted and painted it. Both trans. and TC shift great.

 

Got the pto back together and installed on transfer case today

 

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I am running out of things to rebuild before starting the chassis assembly, so I called the machine shop and told them I wanted to get the engine block of the V6 odd fire cleaned and prepped and he laughed at me! Said " why the heck are you bothering with that thing " guess I will rebuild the winch Instead lol.

 

Nos front bumper came today from willys motors

 

:drool: