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Thread: M135 M211 2 speed transfer case mod

  1. #111
    Colonel DUUANE's Avatar
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    Default Some time to play in the shop

    I got to fitting the mainshafts in the tcase tonight. Things look good. I had the machinist remove .25" from the mainshaft sliding gear ( that engages the drive or the pto) and it looks like that was too conservative. The gear is still too long to allow a safe neutral between ranges with the new gear. I will have to remove another .125" minimum. For an unskilled operator removing a total of 7/16" would be way safe.
    Pic 1 low range engaged
    Pic 2 where neutral will be
    Pic 3 high range engaged
    Rotation is good in both ranges so this part is a win.
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    Last edited by DUUANE; 04-13-2019 at 02:12.

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  3. #112
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    Default The weak link

    Im calling this a win also despite being extremely frustrating. Its a win because it fell apart litterally in my hands as i went to slide the rear output shaft through the bearing retainer.
    This is the cone that the wedge bolts tighten against to load the rear output bearing. The TM says torque to 20-25 lb/ft..you better hope you've had your wrench calibrated and you only pull it with 2 fingers..the cone is a CASTING ..i cant believe GM would cheap out on a critical part like this. Why would you not machine a piece? I am so glad i found this now before it grenaded under load.
    I suggest everyone inspect this part. What a p.o.s. ...you can see in the pics where the load from the wedge bolts split it.
    I'm going to have a new one made out of 4140.

    I'll try and play with the shift forks and rods tomorrow if time allows.
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    Last edited by DUUANE; 04-14-2019 at 03:04.

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  5. #113
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    Default

    Main upper output seal number 2276335
    Input seal number 415449
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    Last edited by DUUANE; 04-13-2019 at 17:18.

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  7. #114
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    Default

    Looking real Good !
    It would be nice if you could take pictures of all the new and modified parts you have. Have them layed out next to the old parts if possible. Also how much has this cost you to date ?
    Thanks for sharing this great project !

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  9. #115
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    Default

    I have about 400 Cad plus my time into it so far. A friend is doing the machining on the cuff so it would be higher if he would accept some cash..he enjoys being in on the dark side of restomod lol.

    If i was building the next case at shop rate i would figure the hours like this.
    Cleaning and teardown - 3 hours
    Modify case - 1.5 hours
    Machine sliding gear - 2 hours
    Machine bearing cone - 1 hour
    Cut new gaskets
    Re & re seals - 1.5 hours
    Make new shift rod - 1 hour
    Modify shift fork - .5 hour
    Fabricate new cover - 1.5 hours
    Assemble unit - 2 hours

    Plus the cost of the shift rod stock,new gear and seals. This is assuming that youre starting with a good case with no damage. 14 hours total labour.

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  11. #116
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    Default

    A note to say good work, keep it up. I think I have an excess of back burner projects already, but this sure would be neat...

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  13. #117
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    Default

    Duuane, do you want another transfer case? It is missing the ebrake carrier/output bearing mount.
    03-1943 g-7123 COE 4x4 REG# 3219442
    02-1952 M135 w/winch REG# 41144752
    My YouTube Channel https://www.youtube.com/channel/UCiU...7Zp-jBw/videos

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  15. #118
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    Default

    Some pics of the stuff on the back bumper here this week..my life is like a shotgun shell full of rock salt...sprayed some green goodness on the M1028 K30 chassis for my M37 project, built supershackles for same. Picked up a fuller rtf9509A and stuffed it in the shop..picked up a holmes formula 1 boom..and hammered apart a standard bore marine '67 small journal 327 for a future 302 buildup...now on to the transfer case stuff..
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    Last edited by DUUANE; 05-17-2019 at 04:38.

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  17. #119
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    Default

    Pm sent on the tcase.

  18. #120
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    Default

    K so i got the sliding gear cut down a bit more..all looks well..there is enough space now so that the two gears can never be engaged simultaeously..that being said a careful hand will be required as there isnt a huge amount of clearance between hi and lo..so if you were in a hurry and pulled hard there is the potential you could bang the gear befor it has time to slow down( as with any case really).
    I also have the new spacer/rear bearing preload cone in shiny 4140..just need to find my split bearing pullers and go at it. My kingdom for an induction bearing heater..more to come soon.

    Cheers friends
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