hmm... i just read something on another forum that says its better to weld the nut to the gear instead of the main shaft...

what are the thoughts on that? the theory is that it's replaceable if it ever fails and would probably help keep the 5th gear from wobbling, but the obvious down side i see is that if the threads on the nut strip it will still come off...

so welding to the main shaft's best asset is also it's worst. and that's the permanent nature of the solution.

still looking for a nut to buy. do dealers keep this thing in stock? napa?

 

just ordered the tool and nut from quad 4x4. $180 to get it to me tomorrow or $130 to get in a week... maybe. seeing as spring break is over after this week and if i don't get it done this weekend we'll be carpooling next week and that will cost more then $50 in gas... so... next day air it is.

 

I have never heard of the threads stripping, just the nut backing off. I like the idea of welding the nut to the gear, because a replacement gear is WAY cheaper than a replacement mainshaft.

 

those threads are definitely stripped. but i wonder if mine was over torqued, cross threaded or something like that during assembly. i'm still in disbelief that a gas motor could have done this at all.

if stripping threads is really something that never happens than i feel better about welding to the gear. even if the cost isn't an issue, not having to replace the main shaft would save a TON of labor. and that alone is worth it.

i think i'll do that. just for the piece of mind. once i torque it down i'll put a small stitch weld on each side of it. to hold it there. something that won't break, but that i'll be able to grind off if removal ever becomes necessary.

now, getting the gear back on... obviously i can't put my press under the jeep and press it back on, can i just whack it back on with a dead blow hammer? or will that hurt the bearings on the mainshaft?

 

Considering what they are designed to do..... I don't think knocking it back on with a hammer will hurt anything.... all the parts should be able to shake off that kind of abuse like water off a ducks back.

 

http://www.youtube.com/watch?v=OxoCjTqAzRg

 

parts reportedly came in today. gonna try and get 5th gear on tonight so i can resume the normal part of the swap over the weekend.

 

well there it is.



although if i'm honest, that thing was mother f*cker to get on. i don't know how these things back off it took all of my strength to get it on there using a 2 foot cheater bar. but it damn sure won't back off now.

other things of note...


here is where the shifter hits the dash. i'm going to cut it and bend it back as low as possible. but i shouldn't have to cut the dash and with some slight modification, i'll be able to use the stock skid.


i also cut the tunnel a little further forward and got another inch up on the transmission. but any further up would require major tunnel re construction and i'm not that dedicated.


and


and finally here's the start of the modifications to the skid plate. i could have gotten away with using a transfer case drop kit, but i decided i'd rather contain the loss of ground clearance to the smallest area possible.



it's only tacked on now and after some test fitting i may reduce the depth of that bracket. i'd rather make it too big and cut it down than make it too small and waste the effort.

i only had one day to work this weekend, so not a lot got done. i'll have more to come as i get it done.

 

Looking good! That shifter really is stuffed up there, I am curious to see what you do with it.

 

i plan to cut the upper part of the shifter off and weld a giant 3/4" bolt to the top at an angle.
like this:





then weld a 3/4" coupler to the bottom of my shifter stick so that it threads on like factory. and if necessary put a slight upward bend in the shifter once it's out from under the dash.

kind of like a more swept back and exaggerated version of this: