Once Again.... LOTS of pictures, so it will take a minute to load!

  I was getting tired of the Jeep dripping everywhere!!!   This was not a problem when I first got the Jeep, but I made the mistake of cleaning everything really good.... big mistake.   So now I had removed all of the caked on oil and grit that was sealing everything and it started dripping.   I ordered the gasket set for the transmission and transfer case, and now it was time to pull everything apart and re-seal it.

My main concern was that we would pull it apart and find that oil was leaking from the rear main seal of another part towards the rear of the engine.   I figured that if we pulled it apart and found a leak, I would have to quickly order one or try to find it locally.

I wanted the Jeep to only be down for a week at the most, so time was of the essence!
First you have to remove the inside covers.   Here you can see the first cover off...

And here the second cover is off.   This makes it way easier to get access to some of the bolts.

After this, it only takes about 15 minutes to finish getting it ready to remove.   I would have two people to remove the two units, but I did it by myself without too much problem.

OK, so I thought I could unbolt the transmission from the bell housing and slip it out, but the clutch fork and a spring snap on, so I will have to pull the bell housing anyway.

This is not a problem, as I want to clean it and inspect the clutch, and the back of the motor for oil leaks.
Here it is!!   As you can see, it has many years of buildup.
After pulling it, I started with the first cleaning.   I used a small wire brush and 3 cans of degreaser, it was a good start.

As you can see, there is still some areas that need work, but you can start to see metal here and there!

I am also starting to see more and more O.D. Green!

 

--End of Day 1--
Another picture after the first cleaning....
The second cleaning took a few hours.   Here you can see what I was taking off.... years of buildup!!
Here it is.... it is not perfect, but pretty good.   During the re-gasketing, I will be doing some spot cleaning.
There are also some areas that are hard to reach, and I will get them later also.

Here you can see the model number.

The small plate held on by screws was not even visible because of the gunk....
If you flip it upside down, you can see that it reads 1-18-51, I am guessing that is the date it was made, since the Jeep is a 1951.
I ordered the gasket sets a while back, so I am ready to go.

Here is what is in the Transfer case bag....

The bottom gasket is for the unit that has the front output and the two shift levers on it.

 

 

Here is what the Transmission set has.

Not pictured is the Seal for the Transmission input shaft.

 

--End of Day 2--
So tonight I figure I will run out and quickly split the tranny and transfer case... quickly?  Yeah right!!
So I remove the 5 bolts holding it together, but it only comes a little way apart... why wont it come apart?
OK, so I will pull the top cover and see what I can see.
Hummm.... looks like it should come apart...

OK, so I pull the inspection cover on the transfercase case and see that there is a nut, holding on a large gear, and I assume that is what is holding it together.   Here you can see the arrows pointing to where the nut and gear, and the place where they go in the transfer case.
OK, S*#T!!  This looks bad, and what are all those small things falling into the bottom of the case?
These are the small things.   A bunch of rollers, and a key lookin thing.
Ho-Hum... I'll just put this back, no one saw anything, who wil know...

OK, so I will wait and seek help from someone who knows about this kind of thing.   

Here you can see the parts....
The arrow shows where the rollers go...   I think that I could put it back together, but I would hate to do it the way I think is right, just to find out when it is all back together in the Jeep that it is wrong.

Here is the transfer case input.

 

--End of Day 3--

5-3-03

Today I decided to get the transmission finished up and sealed.   

First I removed the intake cover and the old gasket.

 
Then I removed the old intake felt seal.
Here you can see the old seal next to the new one.
Once the new seal was in place, I cleaned is up, and got it ready for the new gasket.  
Here is the back side of the input cover. I cleaned it up also.
This was one of the gaskets from the kit.  I first applied a thin coat of liquid gasket, then the paper gasket, then another coat of the liquid gasket.  Doing this should keep all the gaskets sealed up tight.
Here are the clean rollers, ready to go back in.
I put some extra grease on the inside where the rollers go to help keep them nice and sticky and in place until the shaft is back in there.
One by one I put the rollers back in.  The grease worked perfectly and kept them in place.
I them slipped the whole assembly back together.   I put the shifter assembly back in place and checked to see that everything worked fine in each gear.... no problems.
The rear cover just snaps onto place.
Here you can see the bottom of the shifter assembly.  The U shaped forks fit into the slots that I have the arrows pointing to in the next picture.  

Here you can see the whole thing about ready to go together.  The black grease looking stuff is the liquid gasket already on.  

When you move the shifter, the gears slide back and forth on the shafts and that changes how they turn and how fast the rear output turns.

All done!  Next I will do the transfer case.

End of Day 4

Start of Day 5

Today I pulled the bell housing and clutch off.  I wanted to check the clutch and make sure that there were no big leaks at the back of the engine.

The first step was to remove the bell housing.  This was straight forward, no big deal.

Here you can see the clutch.
Next I removed the clutch from the flywheel.
The flywheel was removed, and here you can be the back of the engine.
Here is the pressure plate that was in there... dirty, but otherwise OK.

The clutch fork looks like it was broken and somebody tried to fix it.

I will replace it with another.
Throwout bearing... dirty but otherwise OK.
The inside of the bell housing has quite a bit of oil buildup.

Every once and a while, when you push the button on the floor to start the Jeep, it will grind.  Here you can see the area of the ring gear that has a problem.

The M-38 has a 129 tooth ring gear.  The CJ's have a 124 tooth ring gear.

I would guess that at some time, someone put a civilian starter into the Jeep, and the gear on the starter was wrong and did this damage.

I will attempt to find a replacement ring gear, but if not, I can replace the enitre flywheel.
The tooth on the starter looks fine.
What a difference a little cleaning makes!  
The old clutch disk, with OD green paint and all!!

In the past I have purchased quite a few things from Northstar Willys.  They wanted $150 plus shipping for a clutch set.  I shopped around and the best price I found was at Kragen.... Kragen Online!  

 The regular price for this clutch set was more than Northstar Willys, but the Kragen Online site said it was $101.  I called the local store and they said that they will price match their web site... how nice of them.  

So if you shop at Kragen, always check their website!!  You may get a better deal!!
The old and new pressure plate..

The set also includes the friction disk, throwout bearing, pilot bearing, and alignment tool.

I will be installing it in the near future!!

End of Day 5

Start of Day 6

Took the front shifter assembly off of the transfer case today.

This is the slide gear that engages the front drive shaft. Notice that the right side of the teeth are rounded, and the left side are more square...

I thought this was odd, so I checked the gear that it engages.

It was fine... except that it was missing part of some teeth!

This transfer case worked fine, never made any weird noise, and did not grind.  However, this was a time bomb waiting to go off!

I have a few extra cases and I will have to swap this one out for another.

End of day 6

Start of Day 7:

I found a local shop that would redo the transfer case for about $150, so I went for it.  I ended up replacing the broken gear, a main bearing, and a shift fork.   Here is the unit back together and ready to go back in.

So I now had the issue of the ring gear.   I found a replacement, and heated the old one up and pounded it off.   

To get the new one on, I put the flywheel in the freezer...
.... and the ring on the barbie!  I put the barbeque on high and closed the lid and let it cook for a few minutes until it was REALLY hot, then used welding gloves to carry it to the frozen flywheel.
I was quite happy when it went right on without any pounding!  It darn near fell onto the flywheel!

I also replaced the pilot bushing.

**WARNING**

I was lucky enough to be warned that the new pilot bushings you get with the clutch sets today DO NOT quite fit the transmission shafts!  This would really stink to find out when you are trying to slip the transmission on!   I took a drill bit and just had to enlarge it VERY slightly, and it then fit fine.
I dont have any pictures of of putting the unit back in.   I did it with the help of my 4 year old and was not able to take any.... yes, its true about how easy it is to work on old Jeeps... its just childs play!
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