My Ford Truck Project

joesregalproject

joesregalproject

Royal Smart Person
Nov 4, 2012
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Pittsburgh, PA
The transmission shop called today and told me they had it all fixed up. Turned out a pin in the top cover fell out. Luckily it landed on the magnet and didn't land on a gear. The transmission mechanic told me the synchros and forks looked fine, and that the pin being loose may have been causing that harsh 1-2 and 2-3 shift. They reinstalled the pin and tack welded it in place so it doesn't fall out again.

I'm gonna place an order on RockAuto for a new clutch kit and hydraulic throwout bearing, and the rear trans mount came out in pieces so I'll get one of those too. Also the u joints for the front driveshaft are toast so I'm gonna replace those as well.

Anyways I won't be swapping to a ZF5 for now, just gonna put this M5OD back in and keep it rolling down the road.
 
1evilregal

1evilregal

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Apr 23, 2009
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Greensboro, NC
glad it was nothing major. I had about the same repair that I did for a good friend of mine. she would intermittently lose 1-2, and mutual friends not really knowing manual transmissions, other than changing clutches, left it up to me to repair... turned out to be a roll pin, like yours, but on the fork itself...
 
joesregalproject

joesregalproject

Royal Smart Person
Nov 4, 2012
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Pittsburgh, PA
All the parts came in the mail today from RockAuto. Got a LuK clutch kit and hydraulic throw out bearing, new Moog u joints and u joints bolts for the front driveshaft, bought a transmission mount, and bought a Timken pilot bearing just in case the LuK one turned out to be chintzy (it seems okay but I'm still gonna use the Timken one). Had the flywheel cut this morning at the machine shop. It's gonna rain tonight and tomorrow so I may not get to putting it together until Friday or Saturday, but I've got everything and I'll be ready to go.

Thanks to all who replied to my flywheel thread.
 
pontiacgp

pontiacgp

Canadian Prime Minister
Mar 31, 2006
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Kitchener, Ontario
The transmission shop called today and told me they had it all fixed up. Turned out a pin in the top cover fell out. Luckily it landed on the magnet and didn't land on a gear. The transmission mechanic told me the synchros and forks looked fine, and that the pin being loose may have been causing that harsh 1-2 and 2-3 shift. They reinstalled the pin and tack welded it in place so it doesn't fall out again.

I'm gonna place an order on RockAuto for a new clutch kit and hydraulic throwout bearing, and the rear trans mount came out in pieces so I'll get one of those too. Also the u joints for the front driveshaft are toast so I'm gonna replace those as well.

Anyways I won't be swapping to a ZF5 for now, just gonna put this M5OD back in and keep it rolling down the road.
that is a rare transmission shop who was honest about what the problem was and didn't try to sell you parts you don't need.....:)
 
joesregalproject

joesregalproject

Royal Smart Person
Nov 4, 2012
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Pittsburgh, PA
that is a rare transmission shop who was honest about what the problem was and didn't try to sell you parts you don't need.....:)
They are a really good shop, small, just a guy and his two sons, you wouldn't even notice the place if you just drove past. They've fixed a number of things for me and they've always been great to deal with. They use top quality parts too.
 
joesregalproject

joesregalproject

Royal Smart Person
Nov 4, 2012
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Pittsburgh, PA
Well I got a good bit of work done today, I didn't think the weather would cooperate but the rain held off. I got the flywheel bolted up, the new clutch disc and pressure plate on, replaced the pilot bearing, and installed the new hydraulic throw out bearing.

I had a little extra time after dinner and decided, what the hell, I'll go and get the trans bolted up to the engine. It ended up being a bear.

The bottom of the transmission is rounded, so it kept wanting to roll off the jack. When I finally got it up into place, the driver's side of the bellhousing mated up to the engine, but the passenger side was out about 1/2 of an inch. I could feel that the transmission was splined to the clutch because the output shaft wouldn't spin.

So I ended up starting a bellhousing bolt on the driver's side, and tightening it until I could get the next bolt in, and had to put them in one at a time until I got all 6 bolts in. I don't know what I was hung up on, I'm guessing the alignment dowel, I don't think it was the pilot bushing. Anyways I've got the transmission bolted back up.

With any luck I'll get the rest of it back together tomorrow.
 
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joesregalproject

joesregalproject

Royal Smart Person
Nov 4, 2012
2,245
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Pittsburgh, PA
Well I didn't get as much done today as I'd have liked to. I got the transmission crossmember sitting in place and the new transmission mount attached. There are six bolt total that hold the crossmember to the frame rails, three on each side. I've got all but one in, the holes for one of the bolts on the passenger side just won't line up, which was just pissing me off.

So that's where I stopped today. I woke up with a nasty cold, sore throat and sinus congestion, and I'm sore as hell from wrestling with the transmission itself yesterday, and the temps dropped into the low 50s today, down from the high 60s yesterday.

So being sick, sore, cold and irritated, I decided to wrap up early.
 
Texas82GP

Texas82GP

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Apr 3, 2015
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Hope you feel better soon. You saved that truck. Glad you enjoyed it all summer and glad the issue with the transmission was minor. Get some rest, get healthy and then hit it hard. Hopefully you'll be able to enjoy it a bit more before they start putting down the salt.
 
joesregalproject

joesregalproject

Royal Smart Person
Nov 4, 2012
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Pittsburgh, PA
Thanks man. I should be able to get a little more use out of it before I tuck it away for the winter. It was 80 degrees out last week, now we're in the forties. I swear one day I'm gonna move somewhere warm.

But despite being sick and the weather being cold, I couldn't stand to sit still today, so I went out and worked on it a little bit at a time. First I opened up that last hole on the crossmember with a drill until it was big enough that I could get the bolt through. Then I hooked up the starter and went back inside and rested. Then came out an hour or so later and reinstalled the transfer case and both the driveshafts, then plugged in the electrical connectors and hooked up the line for the clutch. Now I've just got to hook up the shifter and the transfer case lever, top off the fluid in the transmission and transfer case, and then bleed the clutch.

Anyways the hard part is done.
 
joesregalproject

joesregalproject

Royal Smart Person
Nov 4, 2012
2,245
784
113
Pittsburgh, PA
I got pretty much all of it finished today. I reattached both of the shifters, and I filled up the transmission and transfer case with ATF (yeah they take ATF, weird I know). Then I got my dad to give me a hand bleeding the clutch.

Then started it up and let the clutch out, and it moves! I only went back and forth in the driveway a couple times to make sure things were working, but everything seems to be in order. I've got to bleed the clutch just a little more, the grab point feels a little too close to the floor, but that is no big deal. I also have to go back and zip tie a couple wires up and I also want to double check and make sure all the bolts are tight.

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