Replacing the Model 18 Intermediate Shaft

i almost certainly have what patrick says.
but i am gonna count em anyway.
might as well.
i dont have anything better to do......
p.s.
i called warlock and got some expert advice while i was screwing up (again)
his advice is faultless.
my mechanical skills are another matter entirely....

 

Hang in the bill - i don't think you give yourself enough credit - you've done a TON of work to the slug, and i think you've done a great job!

 

herm just called me.
he got my parts i sent him and is shipping the correct ones today.
i asked him about the synthetic oil.
he said DONT DO IT!.
he said that he has rebuilt many trannys that were full of clean syn oil that has no particles in it but the bearings were shot each time.

 

UncleBill,
What is Herm having you use then? I don't drive too crazy just take my time, the synthetic has not been a bother yet. No bearing sounds or clunking noises when I drive. I can only hear the crunch of gravel and dirt under my wheels and the old F banger when I give her the throttle to the next gear. Then the kids and the wife yell when they think we are going somewhere fast. Not!

 

regular 80-90W
he said he doesnt know why but the bearings are always fried when rebuilding a tranny with synthetic oil

 

i got the parts and asked the hotrod guru if i could hire him to do it.
he said NO!
you gotta learn to do this yourself but i will be right there.







what a sourpuss................

 

Gotta learn somehow.
A friend of mine out in LA just got a Ninja track bike, found an old racer/mechanic that will work with him for $200/day doing the rebuild, if Dennis is there to help.
Dennis want's to learn too.

 

If I offer to help, the mechanic boosts his hourly rate by 50%

 

sounds about right double the work being a teacher/mechanic

 

more useful pics
http://www.google.com/url?sa=t&source=web&ct=res&cd=2&ved=0CA0QFjAB&url=http%3A%2F%2Fwww.jeepsunlimited.com%2Fmambo2%2Findex.php%3Foption%3Dcom_content%26task%3Dview%26id%3D43%26Itemid%3D30&rct=j&q=dana+18+rebuild&ei=OJvTS92nDYLUtgOKmsDYCQ&usg=AFQjCNF3lpUvznJ-lWlgoZnj7KxzsmIW6Q

 

herms kit comes with an o-ring like the novacs does.

how in the h-e double hockey sticks does a man install that shaft with ring without shredding it?

(i used a thinner ring i had and then covered both exposed ends of the shaft with THE RIGHT STUFF)

 

the outer edge of this part was broken off and has washers stacked over it so the bolt has a place to get a bite.

 

on one of the gears the teeth are worn a little (no i dont know what it is called).
but since i dont have any money i couldnt replace it anyway,
so i am just putting it back together.
i used that copper spray gasket stuff on the shims.
i dont have a dial indicator either so my hotrod guru kept coming over to the bench and telling me how much endplay i had ( a barely detectable amount).
i am putting THE RIGHT STUFF on all the bolts that go all the way through the case.
i put the snap ring that came with the kit on in the wrong sequence so i had to take it back off and then reinstall it. i hope it works ok because it is spread out a tiny bit more than it was the 1st time.

i havent been taking pictures this time because i got tired of stopping everything to grab my camera with greasy hands.

 

i thought that all those loose needle bearings were going to be hard to do but they were easy.
i used engine assembly grease on them and they stayed in place just fine.
the thrust washers werent to bad either. (took a bit of fiddling)

 

the new copper bushing was WAY too big outside diameter and too small inside.
i used the old one.

 

the bearings all looked fine but i replaced em anyway.
with the new bearings i had to remove 2 of the shims and not use them to get the proper endplay.
so i guess they were worn after all?

 

thanks Jim
i realize it aint exactly rocket surgery to you guys but........