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Green Hell...the Never Ending Project

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

  1. Jan 5, 2022
    Howard Eisenhauer

    Howard Eisenhauer Administrator Staff Member

    Tantallon, Nova...
    Joined:
    Nov 22, 2003
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    8,102
    :(

    That sucks.
     
    johneyboy03 and Lockman like this.
  2. Jan 6, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    2,115
    I had the intermediate gear machined for the same kit, and it was perfect. I have read somewhere that some kit from teraflex were having problem. Herm will check that. Still waiting for him to get the gear (suppose to be there next monday).
     
  3. Jan 6, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    Even more when you know that the gearing was on the sweet spot.
     
  4. Jan 9, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    So found this on marketplace. A complete unit and a complete one in part

    C0E88124-F7FC-45A5-AA93-96F7F8012AC1.jpeg
    need to order some part from novak, plan is too put a short rear 32 rear output. Twin shifter and i plan on a complete tore down and rebuilt.

    B1D9F042-6032-4D50-A6BC-BF18A0CBA04E.jpeg
     
    Fireball and jeep peep69 like this.
  5. Jan 10, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Jan 15, 2011
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    Been struggling if i put back my old dana 20 (but in perfect shape) transfert case back on the jeep.

    I have decided to put it back there since its about a 1 hour job. All parts that i need for the dana 300 project could take time to get here and that i dont want to rush thing out.


    On another subject ,there was some part i bought on christmas day that arrive today. I want to do a complete rebuilt of my front dana 44 (been done in 2017, but as i do a lot off off-road i want to keep thing in perfect condition.. Since i was going to replace the Ring and pignon bearing i will do the carrier. But this too as been delayed since now i want to regear in 4.10 and i need to order them....


    233262415_198228068956507_6261141740303001328_n (1).jpg

    I already installed one in the rear, now i want the front too. During winter i sometime go to my father place where he have a huge playground. Never like to drive with a full lock front and i didnt like to drive with rear only to get there. So now it wont be a issus anymore.
     
    Buildflycrash likes this.
  6. Jan 12, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    After talking with some fellow offroad friend....they convince me to go with 4.56 instead of 4.10 since the gain with be minimal with the work involved.
     
    fhoehle and ITLKSEZ like this.
  7. Jan 24, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Jan 15, 2011
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    Old retired member of our local club as post up some picture from " back in the days" My current frame has been built by one of those member but for a willys jeep with ford engine, transmission and axle. Was happy to get this picture because i never saw before the origin of my frame.

    271099248_478946190497126_952073848206568676_n.jpg
     
    fhoehle likes this.
  8. Jan 26, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    2,115

    Still no answer from Herm :( been two weeks since he receive the gear, send 2 email....just like he ghost me. I feel bad to not having a feedback after a 1500$ expense with him.
     
  9. Jan 26, 2022
    jzeber

    jzeber Well-Known Member 2022 Sponsor

    Morgan Hill, Ca
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    Nov 15, 2003
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    I have had better luck calling him.
     
    Steamboat Willys likes this.
  10. Jan 26, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Jan 15, 2011
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    Every email i send him, i got answer within 24hrs.
     
  11. Jan 31, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    Got news from Herm, he call me today we got a good chat. We agreed that the problem was my set-up in general. Since i have 3.73 gear in the axle and with the 5.3 engine (325 hp) i have put too much stress on the dana 20.

    I told him i was going with a dana 300 and 4.56 gear in the future and he think that it will a way better set-up.

    I knew in my head from the beginning that i would push the limit on the dana 20. I did check over the regear and dana 300 option but i went the easiest way in term of work requirement.

    Going with the tera low on the dana 20 was easy since i just have to swap out transfert case.

    With the other option, i need a dana 300...an adapter, new drive shaft component and other part for the dana 300. Also i need to change gear in the axle.

    I now have the dana 300 but i will wait in 2023 for the swap. This year i will only do the re-gear with the 4.56. I have an electric locker i want to install in the front so the re-gearing at the same time wont be too much work.




    On the other side, i want to do some bodywork before spring. My front drive fender is rust out. I'm looking over Aqualu hard body division and they have front and rear 7" fender. I also plan on a complete paint job. Looking over line x product. I have to get information on that but my plan for the moment is green for the body and hood, black for fender, front grill and windsheild. I'm going to eliminate all chrome parts.

    272220006_1724561291226625_6347198412437293164_n.jpg 272067050_690680945294475_7055747230233633197_n.jpg
     
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  12. Jan 31, 2022
    Buildflycrash

    Buildflycrash More or Less in Line. 2024 Sponsor 2022 Sponsor

    Gulf Breeze FL...
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    Not hitting the like button on this post.
    Do like that your fixing it! You guys didn't tell me when I started but these Jeeps are a lot of work!
     
  13. Jan 31, 2022
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
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    I have a really hard time believing that. I’ve seen D20s handle way more power than that in race conditions. The wear pattern on those gears was pointing to a design flaw, not a setup problem. Sounds like someone was just covering their butt.
     
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  14. Jan 31, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Jan 15, 2011
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    Yes, but for myself i dont see it as "work", but more as a hobby.

    and as you said, i never tought it will so much time involed in the hobby ahh
     
  15. Jan 31, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    They said they have rockwell the gear and there is no problem from there. But i would say it a design flaw from dana on how they work the gear change. Going low to high its the complete gear unit that move. So gear to gear are only holding strait together by the shift rail. Under heavy load you have chance that shift rail goes out of gear or misalign. I run 36" tires with 3.73 fully locked front and rear axle.

    the big of the wear has been done by me….i know i had an issues in the transfert case and i wanted to keep on offroading that day when i should have put it back on the trailer. If so damage would have been minimize and i could have find a sollution.
     
  16. Feb 3, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Was scrolling down facebook yesterday and found out a new hood on primer. Since mine would need a lot of work to make it look good for a 150$ i cannot pass on it. Just need to find a moment to grab it (about 1h30 away from me)

    259061341_756624681970178_165314565453384972_n.jpg

    272482354_637355684247370_6659772540594980615_n.jpg
     
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  17. Feb 9, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    I took another look last night over my empty dana 20 that i use the tera low gear. I found the problem and i'm not happy about the previous owner of that transfer case.

    I dont know why i didnt see that. The front output retainer that hold the shift rod in place has been modified or something like that. I don't know why i didn't see that when i put the transfer case together.

    The hole where the detent spring and ball for the rear output has been drilled, So the ball wasn't holding the shift rail in its perfect spot. Underload it would have made the gear misaligned causing the trouble over the gear.

    267180287_447526550303698_5770247660511758373_n.jpg

    263816708_4712609405493910_9020908388867597177_n.jpg
     

    Attached Files:

  18. Feb 12, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Part for my spring bodywork start to get in :)

    273029378_384861430113899_6104399864884716778_n.jpg
     
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  19. Feb 15, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Got my tube fender from aqualu. Try a little mock up yesterday. Will need some work to make it a perfect fit. Inner fender is rubbing again the steering shaft but other than that i will an easy fit.

    272240660_359921459469028_653018406029379142_n.jpg


    272738217_640569657204612_4923188949032784997_n.jpg

    272444620_680445793371374_5779637469414073195_n.jpg
     
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  20. Feb 16, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    So driver side fender is almost 100 fit. Beed to work out the inner fender because is was touching the steering shaft.

    273024957_494069235558497_4453962149398485612_n.jpg


    273929470_1114906525717917_7735618701263501328_n.jpg

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