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'65 Rubicon Rig

Discussion in 'Builds and Fabricators Forum' started by timsresort, Dec 27, 2020.

  1. Feb 10, 2021
    pat w

    pat w Member

    washougal wa
    Joined:
    Dec 25, 2015
    Messages:
    97
    I was under the impression some 20s had the fill in the rear while others had it on the side? I could be wrong but either way would be a good idea to check the case before you start building
     
    timsresort likes this.
  2. Feb 10, 2021
    givemethewillys

    givemethewillys Sponsor

    New Kent, VA
    Joined:
    Jun 21, 2005
    Messages:
    1,456
    I think you're right. The Dana 20 I had from a J-truck had the rear fill. I have extremely limited experience with dana 20s, so don't definitively know the answer.
     
    pat w likes this.
  3. Feb 10, 2021
    timsresort

    timsresort Member

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    133
    Yes, the 20 case is slightly stronger, and it is easier to find than a large hole 18. And this one is here, free, and looking for a new home. And I was happy to find that it has the oil fill hole in the right spot, as that is a small issue. And yes, all the 18 guts go right in it, with a new Novak master rebuild kit, (with the best and hardest intermediate shaft available). I have done this on my other 2 jeeps. I figure this case survived whatever high horsepower, jumping escapade that stripped the gears, so it has already been stress tested way beyond whatever we will put it through.
     
  4. Feb 10, 2021
    timsresort

    timsresort Member

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    133
    I posted above, but yes some are on the rear, I was lucky that this has the side fill.
     
    pat w likes this.
  5. Feb 11, 2021
    timsresort

    timsresort Member

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    133
    Only had a little time after work, and the water pump showed up, so that is the perfect 1-beer job.
    [​IMG]
    I have been using stainless bolts for the water pump and timing cover to avoid the corrosion that happens. These bolts had been in here for 15 years, and were clean as a whistle, so back in they go.
     
    Muzikp, Fireball and locrwln like this.
  6. Feb 13, 2021
    timsresort

    timsresort Member

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    133
    If it seems like I've been jumping around a lot, you're correct. But, time and parts availability drives this, and luckily, I have plenty to work on. Today is Saturday, 4 speed day. This Muncie SM420 was in a friend of my dad's '57 Chevy pickup , with the Napco 4WD conversion. He did a resto-mod on the truck in the 80's, and this 4 speed wandered its way into the Tux on the last refresh. It has the Novak 1 piece main shaft, and Novak Dana 18 adapter. So naturally I ordered up a rebuild kit from them, after researching which generation of 420 I have, by casting numbers and external characteristics.
    [​IMG]
    After refreshing myself on the procedure with the detailed instructions included, I started the tear down. The only reason I am diving into this is the random jumping out of second under power. And before I pulled the main shaft out, I noticed that it has .015 end play, suspicious, but not sure. Everything that I see is really nice, no smoking gun here.
    [​IMG]
    A little surface rust on first gear, nothing that won't clean up. And the sound of needle bearings dropping into the case as I pull the main shaft back, that indicates the point of no return.
    [​IMG]
    Pulled the snap rings and pressed the shaft out of the gears.
    [​IMG]
    I was happy to see the 1st sliding gear that has the 2nd synchros inside is serviceable, as I don't believe I am finding this part any more. Also, looking at the main shaft, what a nice piece of aftermarket support from Novak. We are lucky to have this kind of equipment available to us old jeepers.
    [​IMG]
    Main shaft back together with new synchros, thrust washer, snap ring. It turns out it's really not rocket surgery.
    [​IMG]
    The difference between a large hole and a small hole adapter is this rear bearing retainer. This is what indexes the transfer case. I totally over looked the need for this, but, for once, I found the large hole retainer in my Dana 18 box. In the bag, with snap ring.
    [​IMG]
    Installed the adapter and front input with gasket but no sealant, checked end play, which is like .002, so sealed it up. Installed the large hole retainer and the transfer input gear on the back. I installed the top on it temporarily, shifted through the gears. I think it's good to go.
    [​IMG]
     
    locrwln, jzeber, 47v6 and 2 others like this.
  7. Feb 14, 2021
    47v6

    47v6 junk wrecker! 2021 Sponsor 2020 Sponsor

    USA
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    Oct 25, 2006
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    5,111
  8. Feb 14, 2021
    timsresort

    timsresort Member

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    133
    Thank you Chris, I did read that last weekend. Great writeup, and detail.
     
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  9. Feb 14, 2021
    timsresort

    timsresort Member

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    133
    Unbolted the motor from the stand, hefted the big flywheel on to the crank, Loctite and torqued.
    [​IMG]
    Installed the lightly used clutch, and the bellhousing. Changed the throwout arm to the Novak push style used with the hydraulic clutch. Time for a wedding (on Valentines day, no less).
    [​IMG]
    Together again, and I am happy to be almost ready to drop it in. And it is nice to have the giant yard sale of parts get cleaned up.
    [​IMG]
     
    73 cj5, Fireball, Downs and 3 others like this.
  10. Feb 14, 2021
    givemethewillys

    givemethewillys Sponsor

    New Kent, VA
    Joined:
    Jun 21, 2005
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    1,456
    I've got a question for ya, since I'm days away from doing the same thing.... what is the spec on the flywheel bolts? Is it anything special? Grade 5, grade 8? As far as I can tell, the clutch bolts are "special", but luckily I have them in a marked baggy. The flywheel bolts weren't so lucky.
     
  11. Feb 14, 2021
    timsresort

    timsresort Member

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    133
    The flywheel bolts are special, I believe 3/8-24 thread, with a big head, like 11/16. The torque is 50-65 lbs. Hopefully you can find them. The clutch cover bolts were standard 3/8-16 grade 5.
     
  12. Feb 14, 2021
    Jeepsterjim

    Jeepsterjim Member

    Lincoln, CA
    Joined:
    Apr 25, 2019
    Messages:
    256
    TIMERESORT
    If ever heading towards Sacramento, please make time to come by for a visit. I live in old town Lincoln. Chris "partsdude" bought tons of Jeepster parts from me.
     
  13. Feb 15, 2021
    givemethewillys

    givemethewillys Sponsor

    New Kent, VA
    Joined:
    Jun 21, 2005
    Messages:
    1,456
    Thank you for letting me know! I have a big pile of bolts that came with my old engine, so I'm sure I have them somewhere
     
  14. Feb 15, 2021
    timsresort

    timsresort Member

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
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    133
    You mean Sam (Partsdude)? He's my brother.
     
  15. Feb 15, 2021
    Jeepsterjim

    Jeepsterjim Member

    Lincoln, CA
    Joined:
    Apr 25, 2019
    Messages:
    256
    CRAP, I stand corrected! Miss seeing him. Trying to work up a surprise for him but "murphy" gets in the way.
     
    timsresort likes this.
  16. Feb 16, 2021
    timsresort

    timsresort Member

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    133
    There is some work to do on the frame around the crossmember mounting area. I want to beef up as much as I can, as I have had some issues with the stock frame in this area with my 3B. In preparation for this, I found the SN stamped in the top of the frame, near the passenger side spring hanger.
    [​IMG]
    Which made me go out to the body under the tarp to look at the body tag. Not that I had any question, but nice verification.
    [​IMG]
     
    47v6 and ITLKSEZ like this.
  17. Feb 17, 2021
    Tyler Vaughan

    Tyler Vaughan Mr. Vaughan

    Central NE
    Joined:
    Oct 20, 2020
    Messages:
    537
    nice! (y)
    matching frame and body, means they're meant to fit together... somewhat.
     
  18. Feb 18, 2021
    timsresort

    timsresort Member

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    133
    Looking at the crossmember, there are some items that are no longer needed, and will need to be removed for the upcoming torque arm mount. The clutch spring bracket and torque reaction cable mount need to go.
    [​IMG]
    I am going to do some beefing up of the frame here, so several unused holes are cleaned and ready to weld up.
    [​IMG]
    Both sides welded, and now I have a clean slate for some structural work.
    [​IMG]
     
    locrwln likes this.
  19. Feb 18, 2021
    Jay's WWII Jeeps

    Jay's WWII Jeeps Member 2021 Sponsor 2020 Sponsor

    Napa CA
    Joined:
    Mar 14, 2018
    Messages:
    128
    Tim
    It looks like a stock CJ5 cross member, how are you attaching the SM420 to it?
    Thanks
    Jay
     
  20. Feb 18, 2021
    timsresort

    timsresort Member

    South Lake Tahoe CA
    Joined:
    Jan 22, 2014
    Messages:
    133
    Jay, the Novak adapter has a boss on it that allows mounting to the crossmember. I made a spacer to adjust height. I'll post some photos this weekend.
     
    Jay's WWII Jeeps likes this.

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