Regarding the installation of the OD unit to the gearbox...
It sounds like a lot of people have bent or broken adapter plates trying
to get everything aligned and back together. When drawing the OD unit
home by tightening equally the nuts on the two long studs, if everything
is aligned properly at no point does the unit get hung up. If you
experience any binding, especially in the last inch +/- 1/2 inch, STOP.
Either the splines are not perfectly aligned, or you are fouling the
pump plunger. Evenly back off the two nuts, remove the OD unit and start
again. Failure to do this will bend or break the adapter plate, or if
you are hanging up on the oil pump, you will bend the plunger shaft.
For years I followed the instructions out there on installing the OD
unit to the gearbox, install the springs on the sliding member, then
offer up the OD unit. Some like to do it with the gearbox vertical, some
prefer horizontal. Both methods can be a huge source of frustration, as
the springs hold the OD unit pretty far from the adapter plate. As Mike
Hado point out, once the springs are under pressure, they are locking
the cone clutch in place on the annulus. One would think that is a good
thing, you have aligned the splines using a dummy mainshaft, not moved
anything, in theory it should just slide right home. Well, several folks
here have posted, more often than not, it doesn't.
Once Tim Hutchisen turned me on to the process I described on my
original post, aligning everything with no springs installed then
stuffing the springs into place, mating the OD unit to the gearbox
became pretty easy and frustration free. Sure, it's messy as you can't
avoid get the sealant on your gloves/hands, but it works every time. One
thing I didn't mention as I thought it was obvious, but this is done
with the gearbox horizontal, on a gearbox stand or the bench.
Henry Frye
On 2023-09-21 17:47, M&M Hado wrote:
> It's not just a matter of rotating the rear flange as you might think.
> If the inside clutch face is against the annulus taper, both splines
> will rotate together when the rear flange is turned. In order to get a
> relative movement to re-align them, the clutch must be pulled away from
> the annulus so the two can rotate separately until they are realigned.
>
> Mike Hado
>
> From: John Lye
>
> Henry says " you need to line up two sets of splines in the OD unit "
>
> This is very important, as I learned the hard way the first time that I
> put
> an OD back together. I thought that I had the splines line up, but in
> fact,
> I only had the first set lined up and snapped a plate tightening it
> down.
>
> On Thu, 21 Sep 2023 07:29:34 -0400, yellow04 wrote:
>
> Joe,
>
> Assembling the OD unit back onto the gearbox is where the real fun is,
> you need to line up two sets of splines in the OD unit, compress the 8
> springs and make sure you don't foul the oil pump plunger on the cam.
> Many ways to accomplish this, some are tedious, frustrating, and can
> completely drive you crazy. The easiest way I have found is to safety
> wire the pump plunger, install the pump drive cam and make sure it is
> pointing away from the pump, apply the sealant to the gasket and place
> in on the OD unit, align the splines in the OD unit, (a spare OD
> mainshaft is really helpful with this) and offer up the OD unit to the
> box. Slowly slide the unit on assuring everything is lined up until the
> gasket is almost touching the adapter plate. Then, install the nuts and
> washers on the long studs only a couple of turns. Then you slide the OD
> unit backwards WITHOUT TURNING the rear flange until it hits the nuts.
> Then you install the 8 springs in their correct position, (shorts go
> inboard, longs go outboard) by stuffing them onto their posts on the
> sliding member then levering the other end onto the nubs on the adapter
> plate. Take a really good look to make sure you have all 8 springs
> correctly installed, then tighten the nuts equally to draw the OD unit
> home. Then install the 4 nuts and washers on the short studs, remove
> the safety wire on the oil pump plunger, refill with oil and you are
> good to go.
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