The School Bus Moved

  
Sadly it did not move under its own power. Thank you Gord’n and the crew at Lamorna Garage is Seattle for letting me store the 109 in your lot. Thanks to Erich Neal for housing it this year.  

    
Erich Neal is the current owner of a very cool 107 Wagon. Every time I see it has has added a new modification. I love the raised hood. 

  
One more pic of my janky oil filter adapter. 

 

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Nv4500 part 600

Setting the torque was very tough. Lowering the lift beam on the housing keep it steady enough to torque the nut. 

Copious amounts of Red Loctite prior to installing the nut for the last time.

Keeping the housing steady.

Use a punch to set the brass disks in place.

Torque the set screws in place. Be sure to Loctite the set screws prior to final installation. 

After the set screws are torqued down use a pinch like this to set the nut collar into the keyway.

Installing the set screws for the final time. 

Sharpie marks to keep track of how far the pieces move during final torquing. Notice the witness marks on the nut lands. The custom socket we made worked well.

Setting the collar into the keyway.   

The two washers moved this much during final torquing.

 

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Remote oil filter

The stock oil filter port for the Cummins 6at block I have will not clear the right frame rail. 

I have used the stock oil filter attachment to make an aluminum plate 

The bolt holes are 11/32 matching the stock filter port 

The remote filter kits use 1/2 NPT fittings. 
   
 

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Nv4500 part 500

.004 end play. Absolutely perfect. .002-.006 is the allowance
Used .017 total shim.

I bought a 1 7/8 Proto socket at Pacific Industrial and modified it to turn the 5th gear retention nut.

I started by turning the rear flat so I could weld on a 3/4 inch drive. I boared out the old star drive so the Modified socket would fit over NV4500main shaft tail.

I then boared out the socket to acomadate the 5th gear retention nut.

I drilled and tapped 3 holes coresponding to 3 glad lands on the 5th gear retention nut. We found a custom socket from a long forgotten project and cut off the 3/4 inch drive hole. This was welded onto the modified Proto socket. 

The shift collars were set to the transmission was in both 1st and 4th gear. This way the gears were jammed and the main shaft could not rotate.

I drilled the first hole a little to far back on the socket. The second hole ~1/16 from the shoulder worked well.

This shim kit from Valley Gear worked perfectly.

The modified Proto socket ready for action. 

Checking end play.

Result .004 end play. Absolutely perfect. .002-.006 is the allowance

Used .017 total shim.

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NV4500 Part 3

Check to verify the main shaft has .002 to .004 end play

IMG_3946[1]

 

 

 

 

 

 

Clean 5th gear retainer nut with break clean and dry

Clean main shaft threads and dry

be sure concave washer has inner portion pointing twards nut

use Loctite 640 on shaft threads

engage two gears in the NV4500 to prevent shaft from turning.

torque nut to 260 – 280 ftlbs

Install brass thread protector disks and tap down with punch

Install set screws with blue loctite to 10 ftlbs

peen collar down into key way

install timm cooper adapter tail housing with anerobic sealer

use silicone in sealed bearing grove

heat housing to 300 – 320 f

install bearing

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NV4500 assembly cont. 

New input seal from Quad 4×4 This bearing race was the perfect size to press the seal into the NV4500 front cover. Cleaned up front cover ready to have the seal pressed in b   Went in very easily. I would not … Continue reading

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Hood extension brackets

In order to fit all this fun and excitement under the hood I am extending it 4 inches. I have designed brackets using Timm Cooper’s guidance that will support the hood properly. Below are the first pieces Fresh off the laser.

  

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NV4500 assembly 2 

                                                                                      I am using assembly instructions for a 2004 Chevy Silverado 2500. The instructions were to install the … Continue reading

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Nv4500 / Forbyn Shaft Assembly. 

Work has started installing the new output shaft from Forbyn Brothers. This is part of Timm Coopers adapter kit that mates the NV4500 to the Land Rover Series Transfercase.                                                             … Continue reading

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Transfercase Assembly


NP205 Front Output Thrust Washer

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