Chuzie's monster transformation

[blazinchuck]

yes, that seal is a real good question! hope you get an answer soon...dayum that would suck taking it all apart

[chuzie]

Ended up ordering a seal meant for a 1995 Toyota Previa DLX transfer case. National part number 471950. If you end up doing this swap I suggest you order 2 of these as they take a few days to receive and could prove to be a big problem when you need a spare.

The seal came in a day earlier than expected! Last night I pulled the D20 off and tore down the spud shaft assembly to prep for this seal. Just so you know, this seal is going in to prevent transmission fluid from entering the D20 through the spud shaft assembly. A seal is not included with the ZF adapter as it is designed for a manual transmission.


I wanted to reassemble the parts using the same heating / cooling methods as before but I was concerned about the temperature limits of the seal. I called National and found this seal has a tolerance of -40 / +220 degrees F. The transmission does have the ability to reach the upper end of this spectrum but I seriously doubt that temp would ever reach this seal.

Set the oven to 200 degrees F for the adapter housing and threw the shaft/bearing and seal in the freezer.

While they were all "cooking," I laid on a light coat of blue RTV gasket maker where the seal will rest in the adapter just for peace of mind.



I gave the seal about 15 minutes in the freezer. Remember the open end of the seal goes in facing the transmission. I used a spare piece of 2.5" exhaust tube and a mallet to drift the seal in evenly.



I used the depth function of my caliper to verify it was fully seated all the way around. Next I sprayed a coat of silicone lubricant on the seal lips just to make sure it would stay happy for the duration.



From that point, the rest of the assembly / install was as previously described in the write-up.

For some reason, it only took 10 quarts to fill the transmission. I don't recall if I ever drained the torque converter. I think that would account for the other 3.

A few loose ends to include the cooler lines, exhaust, driveshafts, etc had to be buttoned up, but I ended up taking it for a test drive and it all went well. I ran with the D20 empty, only for a couple miles. I parked it with the drain plug removed. I hope I do not see a red mess on my garage floor tomorrow morning. I think this seal will work out just fine.

I need to get in the programming mode and modify the shift points and maybe adjust the linkage on the shifter slightly as it is requiring me to really put some upward force on the column shifter to get it to that sweet spot between park and a sensed computer error. No biggie.

Tomorrow I need to install my aux cooler, center console, twin stick boot and upload the new program. Also need to order a good transmission filter and a shorter Autometer trans temp sender. The one I have is the longer version and bottoms out in the brass 1/8" pipe tee I am using.

8-)

[broncomatt]

Not sure I would have driven that far with out oil in the tcase, but if its not noisy I guess its ok.
What did you decide on the trans vent?
Great progress, so does this mean it will make URE?
How about a shake down run in the ocala forest? I know of some great deep sand and many narrow trails.

[chuzie]

I found the vents and got em takn care of.

She is running great now.

Thanks for the offer Matt, but I'm driving her to charleston on Saturday. Wish me luck!

[chuzie]

Well I drove the Bronco to Charleston from Tampa today. The trip was 440 miles and I was extremely happy with how things went. The transmission does very well with the gearing. I cruised at 60-65 MPH @ 2000 RPM. I was able to maintain speed up slight grades without downshifting and the trans temp did not go above 160 degrees. My average MPG was 12.5 which is not awesome but I did have a lot of crap backed up for the URE run since the Bronco is staying in Charleston until November.

I was also pleased with my engine temp. Did not even think about going even a degree above 185.

Success is soooo sweet. This swap was a pain in the A** but in the end, worth the ability to cruise on the highway at a reasonable RPM.

[SC74]

DAAAAMMMMNNNNN!!! Congrats on the long trip. I assume you are flying back?

Like you said already... success is so sweet! What a great tech thread on the swap. An 8 hour trip is one hell of a first trip.

[snipes243]

Congrats there chuzie

[chuzie]

Today I found my EEC was fried. Kind of ironic how I was thinking, as I was driving up from Tampa 2 weeks ago, how stupid it was not to be traveling with a spare computer. Well, she has been sitting since I got to Charleston and today I went to drive her around and the fuel pump would not shut off after the self test and the check engine light would not extinguish. I swapped EECs with Chuck's spare and all was well. Thank goodness it did not die on the road.

On a lighter note, the SUPER BADASS PIMP DADDY rear bumper Chuck and I have been working on for about 6+ months (on and off of course) is nearing its final stages. Pics will come upon completion but I assure you it is saweeeeeet! Expect more when I return to Charleston next month.

[chuzie]

Just tallied up my receipts and updated the numbers at the beginning of the writeup.

My total 4R70W cost was.....

$1,980.00


There were additional costs like exhaust modifications and swapping out my headers but I did not include them since the headers were optional and the exhaust modifications were nominal.

It cost a bit more than I had budgeted but I am so pleased with the results.

[chuzie]

Just tallied up my receipts and updated the numbers at the beginning of the writeup.

My total 4R70W cost was.....

$1,980.00


There were additional costs like exhaust modifications and swapping out my headers but I did not include them since the headers were optional and the exhaust modifications were nominal.

It cost a bit more than I had budgeted but I am so pleased with the results.