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Generations 8-9 1987-1996 F150 + 1987-1997 F250, F350

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  #31  
Old 02-27-2021, 09:31 PM
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I get excited when someone saws "sawzall"! Thank you CJ.
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'78 F-150 Lariat

Quote:
Originally Posted by john112deere
I think the lens of time is required to differentiate between the real milestones, and the detours along the way.
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Originally Posted by mrxlh View Post
Strippers, ammo and SKS, wow, that is almost sig worthy!!
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  #32  
Old 02-27-2021, 10:49 PM
cjfisher cjfisher is offline
 
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Yep done with a good ol' Milwaukee (though I do own a Dewalt now as well).
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1997 F350 CCLB 7.3, Eaton Fuller RTO-6610, 4x4, 3.54, 2001 intercooler w/ modified down pipes, Hydra w/PHP tunes, was stock
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  #33  
Old 02-28-2021, 09:54 AM
cjfisher cjfisher is offline
 
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Time for exhaust work.. The prior owner of the truck put a 3 inch round exhaust in the truck which didn’t fit with the new flywheel housing. I lost a little over 0.5 inches^2 of area going to the oval exhaust, but it did fit between the body and transmission without any additional massaging (prior owner had done some sawzall/hammer massaging to fit the 3 inch exhaust). Curving the oval lines around the flywheel housing and transmission proved to be a test of patience (cut, tack, cut, take a tooth or 2 out of my bandsaw blade , tack repeat..).
Rto6610 exhaust R.jpgRto6610 exhaust 1 R.jpgRto6610 exhaust lower R.jpg
As I had the back of the engine exposed, I figured I’d add bungs to each of the up-pipes for the addition of 2 thermocouples (one per side) to monitor pre-turbo EGTs. I'll cover the setup that handles the thermocouples in a later post as it is the latest feature. The Tee also allows me to watch the exhaust pressure driving the turbo.
Rto6610 ports R.jpg
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1997 F350 CCLB 7.3, Eaton Fuller RTO-6610, 4x4, 3.54, 2001 intercooler w/ modified down pipes, Hydra w/PHP tunes, was stock
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  #34  
Old 02-28-2021, 09:59 AM
cjfisher cjfisher is offline
 
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With the exhaust down pipe fitted I started in on the final assembly. A new flywheel, commercial clutch and pressure plate ready to fit. Sure looks nice in there. This is a 14 inch clutch btw.
Rto6610 flywheel R.jpgRto6610 pressure plate R.jpgRto6610 flywheel install 1 R.jpgRto6610 clutch R.jpg
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1997 F350 CCLB 7.3, Eaton Fuller RTO-6610, 4x4, 3.54, 2001 intercooler w/ modified down pipes, Hydra w/PHP tunes, was stock
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  #35  
Old 02-28-2021, 10:04 AM
cjfisher cjfisher is offline
 
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With the clutch and flywheel in place getting the transmission back in was a bit trickier.. with the exhaust down pipe dangling and the engine tilted down as far as I could get it, I managed to slide the transmission up and into place. I used 3 10 inch long 3/8 bolts with the heads removed as guides. I really (and I mean REALLY) dislike the plastic friction plate centering tool (next time I do this I’ll go buy a spare input shaft to use as the centering tool) as the first try I couldn’t get the transmission to line up with the pilot bearing. After about an hour and a half of fighting the alignment in the cold I got the bright idea to lean on the clutch throw out arm to pull the clutch in.. As soon as the pressure came off and the friction plate was allowed to slip, the housings came together and I was in business. As my transmission to transfer case adapter makes bolting the 2 together difficult I pre-assembled them prior to mating the transmission to the engine (sorry no pictures.. my photographer didn’t want to join me in the freezing cold – this happened during Thanksgiving 2018 in Northern Utah). After raising the transmission into position I added the new rear member and bolted it all together. I also put the original rear member back in as extra insurance.
Rto6610 final install 1 R.jpgRto6610 final install R.jpgRto6610 final install 2 R.jpg
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1997 F350 CCLB 7.3, Eaton Fuller RTO-6610, 4x4, 3.54, 2001 intercooler w/ modified down pipes, Hydra w/PHP tunes, was stock
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  #36  
Old 03-02-2021, 08:40 PM
cjfisher cjfisher is offline
 
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Sorry to keep ya'll in suspense...

I have to apologize for lack of pictures in this next section.. I actually did most of the work described here much earlier in the process – long before I put the transmission in the truck. I knew when I started that the Eaton shift tower was going to be too tall and too far back. In my initial guesstimates I figured the shift tower would end up 5 to 7 inches behind the original position. So after taking some careful measurements and sketching the Eaton tower up I started to change the pivot point until I had a reasonable compromise between a reduced height tower and how much “swing” I would have at the top of the shift lever. As my new idea didn’t work with the original tower parts, I designed my own gimble and a friend with a cnc lathe machined a new finger to mate with the shift forks.
Rto6610 shift finger 1 R.jpgRto6610 shift finger R.jpgRto6610 shift gimble R.jpgRto6610 shift gimble 1 R.jpg
A shot of the new shift tower bolted to the transmission.
Rto6610 shift tower R.jpg
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1997 F350 CCLB 7.3, Eaton Fuller RTO-6610, 4x4, 3.54, 2001 intercooler w/ modified down pipes, Hydra w/PHP tunes, was stock
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  #37  
Old 03-02-2021, 08:45 PM
cjfisher cjfisher is offline
 
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The fellow I bought the transmission from picked up a vertical lever/shift tower for me when I drove up to purchase the transmission. As that wasn’t going to work I cut it all up (and down) beat it up with my press and welded it back together as a shortened 90 degree tower.
Rto6610 shift lever R.jpgRto6610 shift lever2 R.jpgRto6610 trans hump R.jpg
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1997 F350 CCLB 7.3, Eaton Fuller RTO-6610, 4x4, 3.54, 2001 intercooler w/ modified down pipes, Hydra w/PHP tunes, was stock
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  #38  
Old 03-02-2021, 10:11 PM
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fatherdoug fatherdoug is offline
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Amazing!
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'78 F-150 Lariat

Quote:
Originally Posted by john112deere
I think the lens of time is required to differentiate between the real milestones, and the detours along the way.
Quote:
Originally Posted by mrxlh View Post
Strippers, ammo and SKS, wow, that is almost sig worthy!!
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  #39  
Old 03-04-2021, 10:17 PM
cjfisher cjfisher is offline
 
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On to the clutch setup.. Typically these transmissions are hooked up with a mechanical linkage, although I have seen a hydraulic setup that bolts to the bottom of the bellhousing on ebay. After digging around under the hood I decided that it might be easier to keep the hydraulic system verses trying to come up with a set of rods and pivots to maneuver the linkage around all the lines, electrical and chassis parts that were in the way. My first attempt was a disaster.. I had measured the bore and stroke of both the master cylinder and slave in order to calculate the correct offsets for the various parts of the clutch linkage. The lever arm on the transmission itself required a linear move of about 2.2 inches to disengage the clutch and squeeze the clutch brake. A little math and here is the first linkage.
Rto6610 slave fit1 R.jpg
All mounted and ready to go.
Rto6610 slave fit2 R.jpgRto6610 slave fit3 R.jpgRto6610 slave fit4 R.jpg
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1997 F350 CCLB 7.3, Eaton Fuller RTO-6610, 4x4, 3.54, 2001 intercooler w/ modified down pipes, Hydra w/PHP tunes, was stock
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  #40  
Old 03-05-2021, 01:33 PM
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I am sooo impressed

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