PO Box 429
Rio Chama, NM 87532
PHONE (505) 927-2219 FAX (505) 367-3360
Friendly Professional Services
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PO Box 429 Rio Chama, NM 87532 PHONE (505) 927-2219 FAX (505) 367-3360
Friendly Professional Services
y se habla español
|
|
|
NV5600 Conversion to Fuller Transmission
Installation Details
Just a few safety reminders: Place your truck on level concrete Use good heavy duty jack stands Raise the truck high enough to fully clear the frame rails with the transmission MUST HAVE a heavy duty transmission jack Even as high as it looks in the photo, it was still an inch too low
Disassembly of the NV5600
In the Cab Remove the cover over the gear shift & trim parts Remove the gear shift If it's a 4 X 4, remove the two screws on the 4 X 4 shift lever On a 4 X 4, remove the 2 screws on the shifter housing
The Chassis and the NV5600 Transmission Remove the drive shaft or shafts if it's a 4 X 4 Remove hoses and electrical harness from transmission Remove the slave clutch cylinder Remove the bolts and bracket from the transmission on the passenger side Place the hydraulic jack and support the NV5600 transmission Remove the rear cross member support Remove the bolts from the transmission bell housing Remove the Transmission Remove the clutch Remove the flywheel Remove the starter (disconnect the battery first) Remove the flywheel housing On a 4 X 4, take off the 2 nuts on the 4 X 4 shifter housing & remove
Preparation Info On a 4 X 4, cut-off the transmission support attached to exhaust Need to use a ball peen hammer to shape sheet metal to clear transmission just in front (engine side) of the gear shift opening
Installation Install Flywheel housing
Install Flywheel and pilot bearing.
Install single disc or double disc clutch
Single disc application
Double disc clutch has two 14" discs, center plate and clutch cover
Complete installation of single disc "pull type" clutch
NOTE: Some manufacturers install wood blocks to apply release pressure on the clutch springs to keep from warping the clutch cover. Be sure to remove the wood blocks after installation. Be absolutely certain that the clutch disc and pilot bearing is aligned. Tolerance is very tight--use an alignment tool or the input shaft its self. Be sure that the tool or shaft engages the pilot bearing.
Be careful--this bad boy is big and heavy
When installing the transmission, be sure that the grease fitting on the bearing is pointing down. Open the inspection cover plate on the transmission bell housing.
Using a hydraulic jack and a wood block, apply pressure to the front engine pulley until resistance is felt. The rear of the engine will be pointing downward about 15 degrees. This provides a good clearance angle for installation of the transmission.
Move the transmission so that it engages the clutch cover bearing. Make angular adjustments with the transmission jack so that the input shaft is in alignment with the clutch assembly. When the transmission is within 1-1/2" of the flywheel cover, reach into the inspection cover and make sure that the actuator forks are aligned with the contact tabs on the bearing.
At this point it is recommended that the gear shift be installed and the transmission placed into gear. The output shaft can then be rotated to feel tooth engagement between the input shaft and the clutch disc. It is also recommended that extra long bolts be on hand to assist in the alignment of the transmission bell housing with the flywheel cover. Slowly move the transmission toward the flywheel cover and check to ensure that the actuator forks remain aligned with the tabs on the bearing. Once the transmission is seated against the flywheel cover, install the bolts. Remove the jack from the front engine pulley and raise the transmission until it hits the cab floor. Lower transmission 1/2".
Install the 28MT starter
As with Most Projects, some fabrication is required, and this installation requires a transmission cross member and an actuator bracket if you use the Volvo "pull" type actuator.
TRANSMISSION CROSS MEMBER In the Ford, Sterling, Peterbilt and Freightliner installation using a 5.9 Cummins with the 6 speed Fuller FSO6406, the engine and transmission are supported by a "pad and ball" support at the rear of the engine & flywheel cover. The transmission just hangs. On the Dodge 3500, there just isn't enough room to install this type of mount.
This cross member took about 5 hours to fabricate.
The cross member was fabricated from 3/8 bent plate and 3/16" X 2" square tubing. The plates were bolted to the frame rails and the the square tube was cut to fit the opening. There was significant warping and the long screws were used to draw the plates against the frame. The bolt placement was patterned from the old NV5600 cross member. School construction card board was used for the pattern.
Slave Clutch Actuator Bracket There are any number of available options for actuating the "pull" type clutch just as there are for the "push" type actuators. The actuator used for this project was from a Class 8 Volvo and purchased for $35.00. The bracket was fabricated from the same 3/8" bent plate as the cross member was made from. The materials came from a local scrap dealer and purchased for $56.00 with enough left over for many more projects. Fabrication time was about 1-1/2 hours. Trying to figure out how to place the bracket and actuator too the most time. The final choice was to mount the bracket from the bell housing bolts and tap the the mount bracket for 3/8-15 bolts. Four 3/8" washers were used as spacers to aligh the actuator.
I don't consider myself a good welder and this is only my second attempt at fabricating something of this sort. All I can say is that the welds are good and the cross member and actuator look clean.
we're not finished yet come back soon
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