Posted by Tim Holloway on Wednesday, February 21, 2007 at 20:53:42 :
I have been doing a lot of work on the Power Wagon lately, and having good results, actually moving ahead! When my jobsite is near home I can usually steal about an hour and a quarter in the shop before having to pick up my daughter from daycare at 5:30. Today my goal was simple, or so I thought. I would re-install my Dennan overdrive. I had removed it a while back trying to isolate an elusive noise. In the meantime I had also rebuilt a transfer case and swapped it for the leaky one that was in there. So far so good.
So today I set right to work to install the overdrive. There is a mount at the lower rear, and another mount at the top front. The overdrive is supposed to be installed in a direct straight line with the transfer case, and thats how it used to be. The overdrive supports also contain my battery box, which is above the overdrive. The top of the battery box is right below the bed. (Accessable when the dump bed is raised) The overdrive was installed when the battery box was built. So, back to the story.. When I sat the rear mount on the rear support I couldnt bring the front of the overdrive up to engage the TC yoke. The battery box is in the way. The other oddity is that the transfer case appears to be about 2" further to the rear than it used to be. When I removed the transfer case earlier, I was quite suprised how deteriorated the mounts were. With the shafts off it would actually swing back and forth. So, there is the beginning of headache #608 The overdrive mounts were built to align with an improperly aligned transfer case. Now with new mounts, it is apparently a couple of inches higher in the rear, and further aft, although I cant understand that one. The overdrive would need to rise about 3" to be in the correct plane. Unfortunatly the battery box wont allow that, and I cant raise the battery box without shaving the tops of the batteries down. I think I know the answer to this (in the negative) but would angling the rear of the transfer case down be a sin? It seems like it would ease the angle of the short intermediate shaft at the same time. With a magnetic protractor I am currently reading 90 degrees on the transfer case rear yoke and 84 degrees on the rear diff. Tipping the transfer case down would (could) equalise these readings.
Arrrggghhh
Tim
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