M135 M211 2 speed transfer case mod

Merle

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Tried posting a few days back, wouldn't let me. Said add one character. Don't know what was going on.

The wasps are really out this year. They love building their nests in the Deuce and the tractor. Have to keep and eye out.

Merle
 

DUUANE

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Well here we are..a paltry 6 months since the last post on my thread..time sure flies when the bosses expect you to actually work.
So i got the main (upper) rear output bearing off, the new preload adjusting ring on and the bearing reinstalled. I also found a cross for the seal. Its a little narrower than the OE one but all the critical dimensions are the same. There is enough room in the housing that you could put a second single lip seal in after it if so desired but i havnt bothered to search one yet( i will edit when i do find one).
The OE seal is GMC # 2276335 it crossed to Timken #410085 .
Hopefully the stars align and the rain stops long enough that i can get the nose of the deuce off and yank the power pak.
Cheers and happy new year everyone.
 

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rustystud

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Well here we are..a paltry 6 months since the last post on my thread..time sure flies when the bosses expect you to actually work.
So i got the main (upper) rear output bearing off, the new preload adjusting ring on and the bearing reinstalled. I also found a cross for the seal. Its a little narrower than the OE one but all the critical dimensions are the same. There is enough room in the housing that you could put a second single lip seal in after it if so desired but i havnt bothered to search one yet( i will edit when i do find one).
The OE seal is GMC # 2276335 it crossed to Timken #410085 .
Hopefully the stars align and the rain stops long enough that i can get the nose of the deuce off and yank the power pak.
Cheers and happy new year everyone.
No such luck on the weather ! The forcasters say rain all this week and into the next one.
 

DUUANE

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*Shakes his fist at the sky* ...i know..now theyre forecasting a week of -10 ..just as we get a bc ferry up on the blocks for an afterlife refit..
So tonight i got the output gear/shaft/bearing support back in. If you have to mess with the bearing preload ring like i did you have to install the rear bearing and preload ring in the rear support, tighten the adjustment bolts to holdt the preload ring in place, then slide the shaft in through the rear bearing and seat it. Then you can install the assembly in the case. I hope that wasnt too confusing.
So here are some pics of the gear engagements.
Sliding gear all the way to the left= high range
Middle position= neutral
All the way to the right= low range.
Nice smooth rotation and acceptable backlash in all ranges.
This part of the deal is done.
Next...make a relief in the new PTO cover that works with the new position of the low range gear. Then shift rod modification. I havnt decided if ill modify the existing rods or get new and scratch build. It will depend on the diameter i guess. If its a standard size then ill probably get new and keep the OE ones for those in need of stock parts.
 

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rustystud

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;-)
*Shakes his fist at the sky* ...i know..now theyre forecasting a week of -10 ..just as we get a bc ferry up on the blocks for an afterlife refit..
So tonight i got the output gear/shaft/bearing support back in. If you have to mess with the bearing preload ring like i did you have to install the rear bearing and preload ring in the rear support, tighten the adjustment bolts to holdt the preload ring in place, then slide the shaft in through the rear bearing and seat it. Then you can install the assembly in the case. I hope that wasnt too confusing.
So here are some pics of the gear engagements.
Sliding gear all the way to the left= high range
Middle position= neutral
All the way to the right= low range.
Nice smooth rotation and acceptable backlash in all ranges.
This part of the deal is done.
Next...make a relief in the new PTO cover that works with the new position of the low range gear. Then shift rod modification. I havnt decided if ill modify the existing rods or get new and scratch build. It will depend on the diameter i guess. If its a standard size then ill probably get new and keep the OE ones for those in need of stock parts.

Looking real good !
Your on the back stretch now ! Don't give up !
Especially as I want that old Hydra-Matic ! ;-)
 

DUUANE

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Haha i know..its supposed to get super (relatively) cold and snow tomorrow..as soon as i can get in there ..im on it. Its next on the dockett..
 

rustystud

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Haha i know..its supposed to get super (relatively) cold and snow tomorrow..as soon as i can get in there ..im on it. Its next on the dockett..
Yeah, where all going to get hit by this new Artic front coming down. That combined with that stupid swirling storm off the coast will make for some interesting weather this up-coming week !
My bet is on 12" of snow here.
 

Dan Boehmer

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Gilbert, Az
Hope your transfer case mod is coming along well. I just stumbled onto this thread and had some information that might be helpful. Tulsa Truck Manufacturing has done conversions of heavy commercial trucks to 6 x 6 since the late 60's. I have a copy of a ~ 1970 TTM parts manual for Ford trucks they converted to 6 x 6 using the drivetrain from an M211/M135. They used a Clark 285 5 speed transmission and converted the M211 transfer case to a two speed by using the PTO drive gear. Attached are some scans of a few pages in the manual showing the transfer case parts and parts list with the new solid PTO drive gear. TTM is still converting trucks in Tulsa today - Tulsa Truck Manufacturing (tulsatruckmfg.com)
 

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DUUANE

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That is awesome! Thank you Santa! I'm jammed up for time so ive stalled out at modifying the shift fork and rods. Any and all additional info is extremely helpful. They asked us to work Christmas eve and Boxing day today 8-Z
 

DUUANE

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Hi all.. So after much delay.. and some vaccinations..I'm back at it while I try and get the shop cleaned up enough that I have room to swing a cat. I took the front shifter rail support apart and it turns out the detent ball for the forward/reverse sprag rod was missing. Not a huge deal I guess. I fitted the high/low control rod, formerly the pto rod, with the fork reversed. It seems like I should be able to grind a hair less than 1/4" off the rear side of the fork and maybe 1/16th off the support in the case and I should be in the happy place for gear engagement with the new low range gear. The control rods should be able to be made from hardened and ground 3/4" round bar or 4140 or some other kind of smooth like butter round bar. there are no bushings in the case so the smoother the better.
Does anyone have a part number for the seals for the control rods?

Here are a couple of pics of the shift fork and case parts that need clearancing as well as the gear engagement at the unmodified stage.gear engagement.jpgshift fork.jpg
 

DUUANE

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So for those that are following and those that find interest. Here are a couple of pics of the modified high/low formerly pto shift fork. I don't have fitment pics yet, It's been back to back projects at work the last month and a half so little time to play with my toys. Judging from the last pics I will have to pull the shafts out and clearance the boss that supports the rear of the shifter rod a bit. It looks like the boss for the bolt that secures the shift fork to the rod may not clear the boss. Option 2 is to change it out for an allen head fastener which I may do. Once that is resolved there may be additional relieving of the boss so that the gears have full engagement. It will also allow removal of some cast in sharp angles that look like pretty big stress risers to me. They will be replaced with a generous radius.
More as soon as I can get to it.
 

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