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Green Hell...the Never Ending Project

Discussion in 'Builds and Fabricators Forum' started by johneyboy03, Nov 6, 2011.

  1. Apr 24, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
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    So now the front is almost complete (except the ram assist) so time to get a look over the transfert case.

    It's the second transfert case that i got problem with the intermediate shaft and gear. The intermeditate gear sit between two trust washer. With time those washer get worn out and it get thinner so you have side play on the intermeditade gear. With side play gear contact is not perfect and it will finish by breaking some tooth.
    IMG_3749.JPG

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    IMG_3746.JPG

    IMG_3748.JPG

    IMG_3747.JPG
     
  2. Apr 24, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
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    So the cure for this problem come from a tapered bearing kit that i order from advance adapter. It doesn't use the roller bearing as oem but use tapered bearing with cup. You need to send the intermediate gear to a machinist to bore down the space for the bearing cup. Instruction give the spec for the boring so it's pretty easy for the machinist to work with.

    IMG_3742.JPG

    IMG_3741.JPG

    IMG_3744.JPG

    IMG_3743.JPG


    I'm still waiting for the twin stick from novak to come in. I found a thread that where it show how to modify the shift rail to keep the interlock pin. I read that taking away the interlock can cause the rear low to disengage, so with the shift rail mod you don't need to worry about this issu. More picture to come when i will start working on it.
     
  3. Apr 27, 2017
    sterlclan

    sterlclan Member

    exploring the...
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    is the tapered bearing kit for the 20 or is it for the 18 with the large shaft?
     
  4. Apr 27, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
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    Kit for the 20 for myself. But advance make one for the dana 18.
     
  5. Apr 27, 2017
    givemethewillys

    givemethewillys Sponsor

    New Kent, VA
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    I'm liking that tapered bearing kit. It looks like it solves the biggest problem with the D-18. Do you lose an appreciable amount of strength in the shaft with the conversion though?
     
  6. Apr 27, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
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    It's a good question, i did a lot of search for the tapered bearing kit over google and the only result i found was a guy telling that he bought a kit for his dana 20 without anymore feedback. Advance told my seller that he's been selling this kit for more than 20 years so it must be good a this point.

    I will give some rewiew after i installed it and run it some time, but my first impression is that a very nice kit that in theory eliminate big issus with the transfert case. It eliminate all the rubbing againts the trust washer so you don't don't get any side play on the intermediate kit.
     
  7. Apr 27, 2017
    sterlclan

    sterlclan Member

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    i couldnt find the kit for a 20 listed at advanced ,did you fab the shaft? or do you have a part number for the kit?
     
  8. Apr 27, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Their website doesn't have all the information.

    DANA18-INT : Intermediate Gear Kit retro fits the Dana 18 With Tapered Roller Bearings for noise reduction & performance | Advance Adapters

    But if you look on the page their is two different installation pdf.

    It seem that only difference over the kit is if you have a 1 1/4" shaft or a 1 1/8" shaft for the dana 18/20. As you can see on top of the link is being written for JEEP DANA 18/20 TRANSFER CASE INTERMEDIATE GEAR KIT.

    http://www.advanceadapters.com/downloads/7160050.pdf

    http://www.advanceadapters.com/downloads/7160060.pdf


    if you are interesed and want to make sure you will have the right kit i would send a email to advance.
     
  9. Apr 27, 2017
    sterlclan

    sterlclan Member

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    thanks for the clarification...
     
  10. Apr 27, 2017
    CJ5Jeeper

    CJ5Jeeper Teacher Jeeper

    Apple Valley, CA
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    I'm still waiting for the twin stick from novak to come in. I found a thread that where it show how to modify the shift rail to keep the interlock pin. I read that taking away the interlock can cause the rear low to disengage, so with the shift rail mod you don't need to worry about this issu. More picture to come when i will start working on it.[/QUOTE]

    FYI..When I purchased my twin stick through Novak (which is actually a JB Fab) they advertised that their kit will NOT pop out like other cheaper twin stick conversions will do. This is one of the main reasons I went with Novak and didn't shop around, or do a homemade conversion. I have a friend who installed one of those cheaper conversions on his early Bronco, and his does pop out. However, mine has never popped out, and I did remove the interlock pill. My two cents is that the Novak conversion is very well engineered, so I would not deviate from their instructions. My only complaint, is that it can occasionally be very difficult to get the front out of 4 high. Regardless of what you decide, you're doing an awesome job and I'm sure it will come out great.
     
    johneyboy03 likes this.
  11. Apr 28, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Thank's for the info, you make me questionning myself now with the background you provide me here. I may do a modification over the rear shift rail. The pocket where the detent ball goes have some kind of ramp (see picture below) for ease of disengage when you have one stick that control front and rear. I may add some material there for a better hold on the rear low with the twin stick.


    [​IMG][​IMG]

    [​IMG]
     
  12. May 2, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Maybe out of subject but i score some toyo open country m/t (35 13.5 r15) for a very cheap price. I will run them as a road set and i will keep the tsl for trail only. With my little daugther that come in february i wanted to have a better tire for the road.

    They still have around 1/4" in the center but for a 300$ deal it's ain't bad.


    18261410_120332000496803078_297720170_o.jpg
     
  13. May 4, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Got some rim from a member of my local jeep club. 10 inch wide with a 4 inch back space. Those at first i got was a 7" wide rim and it wasn't the best for a 13.5" wide tire.

    18195144_1555386517807491_8519000184650877411_n.jpg


    The bottom left one is the worst for the rust spot, all the other has some rust spot just around the center and will need a good clean/polish. So i started to work on the worst one. Did try aluminium foil with water, it got some of the rust but it's not perfert. The orange rust is gone but there is still back spot on the inside lip. Don't know if i can get it back to chrome, i will try a take a picture tonight so i can get a second idea on it.

    For the aluminium i can give a try with some cola or/and vinegar to see if it work too. I also read that salted water is good too. I will give it a try too. If others have better idea you're welcome to share it :)
     
  14. May 5, 2017
    jzeber

    jzeber Well-Known Member 2019 Sponsor

    Morgan Hill, Ca
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    Are they steel wheels or aluminum?
     
  15. May 8, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Steel with chrome plating
     
  16. May 8, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    So worked this week-end to finish my spring work on the front axle.

    With the 1 ton TRE'S and i bigger OD tubing i had problem with the ram assist hiting the drag link when full lock and flexing.

    SO i move the ram assist where it won't get in contact with the other thing.

    here the braket i fab.
    18337107_120332000640855144_1102007825_n.jpg

    18296819_120332000671262757_854535655_o.jpg

    Final result

    18387072_120332000653295114_1129925135_n.jpg

    18360765_120332000654504368_1452007064_n.jpg
     
  17. May 8, 2017
    jzeber

    jzeber Well-Known Member 2019 Sponsor

    Morgan Hill, Ca
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    Hard to tell how bad the rust is but an old trick is to use steel wool on chrome. We used 000 on his chrome and it turned out almost like new.
     
  18. May 11, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
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    Got the twin stock set-up today, but novak just srew up the order. They send me the wrong kit so with the wrong part number.

    Since there a lot a configuration for the dana 20 transfert linkage, i did send Novak some picture of my actual transfert case and they provide me the right shifter kit part number. But when i did the order they have change the kit without telling me when they asked me wich transmission i do have .I told them that i was having a t18B but i did told them that i doesn't have a oem set-up.
    From there as i said they change the kit without noticing me.

    So i took 6 week to get the stuff here, and i'm not able to use it. I may be able to make it work on my set-up but i will require lot a modification and i don't know where the shifter will hang out of the floor....

    And paying around 300 canadian dollars i'm not really happy, i'm not to much into doing modification on something that suppose to be bolt-on.

    Now i'm waiting on a comeback from Novak, but i really mad about waiting 6 more week to get the right product.


    That the kit i receive for:
    dana_20_twin_stick_cj20l.jpg

    Here's the kit i was suppose to receive and what i did actualy order.

    dana_20_twin_stick_cj20s (1).jpg

    I won't be able to use the kit thet provide me...that shifter will hang out under the dash...


    And here the picture i provided to novak....

    17500348_10154182993181621_1384170427_o.jpg
     
    Last edited: May 11, 2017
  19. May 11, 2017
    jzeber

    jzeber Well-Known Member 2019 Sponsor

    Morgan Hill, Ca
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    Sorry to hear about getting the wrong kit.
    When I was doing my SM465 install I had an issue with the parts from Novak. I called and they were great. That was back in 2005 so I cant remember who I talked to back then. I sent the part back, they fixed it and returned it to me. Hopefully you get similar results and get it before 6 more weeks go by.
     
  20. May 11, 2017
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    I will take a look over the kit and i will see i can modify it for my purpose tonight.

    The 6 weeks thing is because they didn't have it in stock, so they need to wait for Jb fab to send it, and after that there is the delay for the customs to get here in canada.

    I already miss 3 trails (we do ride almost every weekend) so i don't want to lose more time waiting for the stuff to come in, summer here is short so i want to drive my jeep before the snow come back. If i'm not able to work with the kit i have in my hand i will simply put back the t-case and transmission as it was and i will wait next year to install it.
     

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