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Green Hell...the Never Ending Project

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

  1. Sep 7, 2021
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
    Messages:
    2,115
    Hi everyone, just wanted to share a little life naustalgia from last week-end. We have each year a 3 day off road week-end always during labor's day week-end that we use to call " Animal Party ".

    My amc 360 engine fail on me on the last day (sunday) last year.

    The picture above has been taken at the exact position where my amc 360 stopped and never started again.

    I had chance to stop just before an exit to the trail, what you can see on left side. I'm happy this year to be able to continu on the right side and finish the trail with my fellow 4x4 club member.

    240501488_10157787662041621_1118962969698765990_n.jpg
     
  2. Sep 17, 2021
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    2,115
    Time to shine :)

    We are celebrating this week-end the 45th anniversery of our local 4x4 club.

    We have an exposition on saturday and a 16h00 we are going to parade trought the city.

    241196359_597218837954991_4535280908564148444_n.jpg
     
    blalp!, Ol Fogie, Fireball and 2 others like this.
  3. Sep 20, 2021
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    2,115
    Happy monday to everyone. Had a nice week-end with the 45 festivity and parade :)


    242325497_2987109168169876_863441652580100249_n.jpg
     
  4. Nov 16, 2021
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    2,115
    I must give a thumb up to Hemr the overdrive guy. I did receive my teralow kit with the intermediate gear already machined for the intermediate shaft kit. Since i live in canada it took me more time to find a way to pay him than to receive the stuff. Paid him on last tuesday, receive them today.

    257274003_294220462434308_8959899972268979119_n.jpg
     
    Last edited: Nov 16, 2021
    blalp!, dozerjim, Ol Fogie and 4 others like this.
  5. Nov 17, 2021
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    So i first started by getting all the parts needed on my work table. I will check for the best part to assemble a complete unit.

    I will leave my current transfert case as a spare units so i will built another on from the ground. As dont have spare part ahah

    255927938_755800039150919_5080430431286813564_n.jpg
     
    KeithR, Fireball, Ol Fogie and 2 others like this.
  6. Nov 22, 2021
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
    Messages:
    2,115
    Little progress on the dana 20 rebuilt. Clean up the front output retainer, and the rear output assembly along with new bearing race.

    After some rust cleaning time for a fresh coat of paint :)

    259401414_1308868212890375_4997486013871391092_n.jpg
     
    dozerjim and Ol Fogie like this.
  7. Nov 24, 2021
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    Got the case ready for gear swap, need to grind at some place inside it. So a freash coat of paint before going trought final assembly.

    transfert case paint.jpg
     
  8. Nov 24, 2021
    Lockman

    Lockman OK.....Now I Get It . 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Silver Hill,...
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    Looks Good johneyboy :beer:

    Did you have a pic of your Tranny Pan Modification that you were gonna look for me?
    Just wonder'n ...
    ....Richie
     
  9. Nov 24, 2021
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    2,115
    oh sorry about that, i will take some, i need to swap transfert case so i will sure post some here :)
     
    Lockman likes this.
  10. Nov 25, 2021
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
    Messages:
    2,115
    Start re-assemble yesterday. Always been struggling about the ball and spring that hold the shift rail in gear. After 45 minutes trying to get those in i got a flash idea. I had other shift rail from transfert case i tore appart. Took you, cut it to about 3.5" made a ramp. Work like a charm, way easier to put shift rail in.

    260787117_10157907404216621_3130405651888559484_n.jpg
     
    dozerjim, ITLKSEZ and Fireball like this.
  11. Nov 25, 2021
    Lockman

    Lockman OK.....Now I Get It . 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Silver Hill,...
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    Good. That's a similar to the way that we R & R some lock plugs . We call it a Follower.
     
    johneyboy03 likes this.
  12. Nov 30, 2021
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    So time to start the transfert case swap. So i remove my stock unit.
    261307016_633514801331283_9100044662524231490_n.jpg


    Advance adapter gave me a big headaches with that problem. With their intermediate shaft kit they provide a castle nut. I wasnt able to get the cutter pin inside the castle since the hole for it is higher than the nut itself. Had to made some shim with washer i had at my job (need some grinding for transfert case mounting clearance.

    257742477_346336637302200_5171209301405256322_n.jpg

    I have the same intermidiate kit on my stock unit. When looking at both transfert case on my work table i finaly found out why i wasnt able to put the cotter pin inside the nut

    261408361_1049608925609214_8026955427139239500_n.jpg

    Dont know why, but advance adatper have change their castle nut as you can see on this picture.

    260417198_3127392280872523_1381679737318226163_n.jpg

    So i just interchange nut and if work as it suppose to be.

    260816182_613087749807008_5311357273121012586_n.jpg


    So now i just need to clean out the mounting surface on the transmission adapter and i'll be ready to put the new unit in place.
     
    jzeber and Lockman like this.
  13. Nov 30, 2021
    Lockman

    Lockman OK.....Now I Get It . 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    Good Job....... Any Tranny pan Pics , while your in there ?(y)
     
  14. Dec 2, 2021
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
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    Here you go. I have a deep alluminum pan that i modified.

    262990693_979439092915284_1294813371256494356_n.jpg

    260823808_3180219842201868_3578018337960242077_n.jpg

    261815088_442931160719471_9077246553559829979_n.jpg

    262202250_604550927331232_7492923129630805776_n.jpg

    260280001_1116932262382271_2108392472950236005_n.jpg
     
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  15. Dec 2, 2021
    Lockman

    Lockman OK.....Now I Get It . 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    Thanks ......That gives me ideas & reference .
    ....Richie
     
  16. Dec 2, 2021
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
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    engine placement is also the key. I have maximized the space when i swap my LS engine.
     
  17. Jan 4, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
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    So first trail with the new transfert case and thing didnt go as expected. The trail didnt last long since their was whinning noise coming from my transfert case in low position. Everything is normal on high speed.

    Put jeep back on trailer and drive home. I took off the transfert case from the jeep only to find that intermediate gear and rear low gear started to eat themself.

    266357396_339353504687631_6098125939867597727_n.jpg

    269867676_250602893761049_8789138964897092851_n.jpg

    For now the only positive side is that I found what gearing I need at the wheel. It was just perfect, but the problem is that it didn't last long :(. I send back gear to Herm for more analysis.

    So now I'm hunting down a solution.
    I Need to get around a 29:1 total ratio if I want to be near the 3.15 tera low kit.

    There's two option for me right now

    First option
    Getting a dana 300 with a 2.62 ratio, re gear the axle to 4.10 (previous is 3.73)
    This way I will end up with a 27:1 total ratio. I will need to upgrade the rear output to a novak short output (for rear drive shaft length)
    Pro: Price is cheaper
    con: Not a huge upgrade in strength for 2/3 price of the atlas
    Involve regearing axle and that is something i dont like to do.

    Second option
    Going with an atlas 3:0 gear, pricey but bulletproof and no re-gear in the axle, keeping the 3.73. So I will end up with a 28:1 total ratio.
    Pro: One piece unit, less work about regearing axle
    More length in rear drive shaft

    Con: unit is bigger than a dana 20 or 300 i may have trouble fitting it between my custom frame.
     
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  18. Jan 4, 2022
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
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    Ouch. What the heck would cause that??

    If I’m spending your money, I’d go Atlas. :twist:
     
  19. Jan 4, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
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    I'll be waiting feedback from herm. I'm searching why it had gone this way.

    Atlas is the easiest choice, but since i'm not sure about space i'm afraid to go there....

    Atlas from center of input to the end of front output side i have 13.5" if transfert case is sitting completly flat (wont happen)
    But know i have 12" from transmission output to passenger frame rail. If i clock it i gain some space but it's a tight fit. I dont have much room to play with engine placement.
     
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  20. Jan 5, 2022
    jeep peep69

    jeep peep69 Member

    redding ca.
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    Long story condensed down on why I won’t deal with Herm ever again .I sent a intermediate gear to him to be machined for the AA tapered bearings kit and got it back and installed and the same thing happened to mine. The gear wasn’t machined concentric as AA instructions specify . It was off set on one end by 0.30 just enough to cause it to self destruct . Sent it back to herm a got told it wasn’t the gear he did that I swapped gears and was trying to swindle him . End of story wish you better luck than I had with him.
     
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