T19 Rebuild in Korea

I used the steel sleeves that came with the mounts, so I don't know exactly how long they are. The polyurethane can be compressed a lot. I'd cut the sleeves so you get about 1/16" of an inch compression on the xmember.

The drive to our home includes 3 miles of patched patches of asphalt called pavement and 1 mile of dirt. Things really get bounced around on that road since it isn't driven slow and there is no issue with the transmission mount or how things are holding up. Everything is tight and solid after 2 years of that abuse.

I'm more concerned about your flywheel and would really like to see some better pics.
 
I used the steel sleeves that came with the mounts, so I don't know exactly how long they are. The polyurethane can be compressed a lot. I'd cut the sleeves so you get about 1/16" of an inch compression on the xmember.

The drive to our home includes 3 miles of patched patches of asphalt called pavement and 1 mile of dirt. Things really get bounced around on that road since it isn't driven slow and there is no issue with the transmission mount or how things are holding up. Everything is tight and solid after 2 years of that abuse.

I'm more concerned about your flywheel and would really like to see some better pics.
 
Had a similar issue with the nosecones. Bought a t19 wide (right side in picture), and replaced the seal and gasket on the nose cone that came on it before I noticed the difference. Input shafts are same length, but clutch disc runs out closer to the end of the input shaft on the inlines. The longer one is for a straight six, possibly a diesel as well. Unfortunately, with the longer nosecone you can't run the longer throw out bearing sleeve, hits the back where the ground part of the nosecone that the bearing sleeve rides on ends (can't adjust it loose enough). Looking for a spare that I can get turned back about 1/4 in more. Those small useless looking furniture dollies they sell at harbor freight for about 14 bucks are priceless for rolling these 160 pound trannies around.
 

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My long nosecone was on the t18 that I just took out of Scout. I have a 304. I put the long one onto the rebuilt t19 that I am about to install.


hondo said:
had a similar issue with the nosecones. Bought a t19 wide (right side in picture), and replaced the seal and gasket on the nose cone that came on it before I noticed the difference. Input shafts are same length, but clutch disc runs out closer to the end of the input shaft on the inlines. The longer one is for a straight six, possibly a diesel as well. Unfortunately, with the longer nosecone you can't run the longer throw out bearing sleeve, hits the back where the ground part of the nosecone that the bearing sleeve rides on ends (can't adjust it loose enough). Looking for a spare that I can get turned back about 1/4 in more. Those small useless looking furniture dollies they sell at harbor freight for about 14 bucks are priceless for rolling these 160 pound trannies around.
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Ok. So flywheel out to be serviced, having new mount bushings made and a spacer plate to set the clutch fingers. IHPA is sending me a new friction plate, to bearing and input shaft bearing. They haven't told me if they can replace the clutch finger adjustment screws, if not I'll have some metric ones fabricated, it is so nice having many reasonably priced machine shops all over town.

So, to keep from being bored, I rebuilt the transfer case. There were no issues except that I couldn't find my dial gauge until I was finished. So lots of install and removes until I got shims right. Here are some pics of the finished product. Of course, short one measly o ring for the intermediate shaft prevents me from declaring it finished. I also have a new high capacity cover that I will install after installing case into Scout.

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By the way, there is a lot of play of the sliding gear over the front output shaft. Like greater than 0.005" in fact each of the spines has a slight step in it just where the sliding gear ends (see arrows) I should have gotten a picture. Anyway, since it is the front shaft I am not super worried for the time being. I don't remember if this happened with my other transfer case. Any opinions?

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Wow. I wrote out a post, attached pics and it disappeared, so try again.

I tried a dry fit of my newly rebuilt Dana 20 to my newly rebuilt and painted t19. I wanted to be absolutely certain that the bull gear seated properly. I measure everything carefully but nothing beats reality.

Anyway I had the tranny standing on its bell housing to make it easier to paint and it seemed best position to dry fit.

So here I am getting on my son's case about not paying attention and gosh darn it the shifter yoke interferes with the tranny body.

It is just one goddamn thing after another. If this job hadn't been so drawn out I might have installed the tranny and found this out under the truck!

So what is going on here? I measure the output shaft of the old t18 and the new t19 very carefully. I even measure the distance from back of the bull gear to the mating surface of the tranny and then compared thiis to the distance from the back of the counter shaft gear in the tcase to the mating surface and got an exact match. The bolt patterns are also the same.

This is a wide ratio t19, the probability of being non Scout is very small, plus did the t19 housings vary over there manufacturing life?

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one goddam thing.jpg
 
We've really got to work out a way to cross reference these threads. One good thing is to come up with a good thread name. I blew it with "clutch question", "t19 rebuild in korea" is better but there's one big issue.

When you do a search, even of just titles, the search page won't let you use a search term like "t19", it must be coded to reject single search terms of 3 characters or less.

I was searching and searching for Tom's thread to see if he encountered my problem.

And btw, I feel your pain. I am so freaking lucky that I found this problem in my workshop. Man, do I feel your pain, Tom.

So, there must be a factory mod to the Dana 20 yoke to accommodate the t19, no?

fdchappie said:
well your swap is going just like mine. Except my trans was installed when I discovered the problem. http://forums.IHPartsAmerica.com/showthread.php?t=10139
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Ok. We can start by adding tags to our threads. When you search tags you are allowed to use "t19" for example
 
What's with that intermediate gear countershaft sticking out of the transfer case? Assuming that groove is for the o-ring, I've never seen one with a small nub for the locking tab like that before.
 
The counter shaft from this rebuild kit has two o-rings instead of one in the original shaft. The smaller bit on the end stays outside so it doesn't matter about the operation of the case. It is also of dimensions that it still picks up the locking plate


Mark pietz said:
what's with that intermediate gear countershaft sticking out of the transfer case? Assuming that groove is for the o-ring, I've never seen one with a small nub for the locking tab like that before.
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I can imagine being overseas has its challanges. Your resourcefullness is amazing. Do you live on base or the economy? :d
 
Looking at that rearmost boss where you have no clearance with the d20 transfer case front cover. There were some variations in the castings for the t19 cases, or at least that's been my experience. My first go-round with a t19/d20 was a boss in this same area (May have been more forward) and I had to grind it down so the d20 would clear the side of the t19 case. Oh, it's important to note that the t19 case was from a 2wd truck and I had to drill the missing holes on the rear of the case so that rear bearing t/c adaptor would mate up. It wasn't a situation of bad clocking, either. The case simply had some extra bumps on its side.
 
Thanks for the compliment. I solve problems for a living. I am a physicist with an honest to gosh phd (piled higher and deeper). I design experimental hardware for a living.

http://capp.ibs.re.kr/html/capp_en/

Got my first Scout in 1986, when I was a kid long island boys wished for four wheelers. Wrenching my scouts is relaxing. I have restored a 1960 vw bus with my daughter.

Bill hamilton's got me beat for resourcefulness but I try to keep up a little

greg r said:
I can imagine being overseas has its challanges. Your resourcefullness is amazing. Do you live on base or the economy? :d
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I asked an expert from another vendor and he said that they have not seen much variations in t19 bodies. In this case since it is a wide ratio it almost certainly was in a Scout.

It had a Dana 20 mated to it with a linkage I never saw before. I took it off so long ago and it is back in the us I don't remember what it looked like. I always assumed that the tranny and tcase were out of a Jeep. I didn't even realize that it was a t19 until I started rebuilding it!

Since the bell housing on it matches mine it would seem that it was n a Scout. However, the nose piece was significantly shorter.

Hoping somebody out there has more to add.

Mark pietz said:
looking at that rearmost boss where you have no clearance with the d20 transfer case front cover. There were some variations in the castings for the t19 cases, or at least that's been my experience. My first go-round with a t19/d20 was a boss in this same area (May have been more forward) and I had to grind it down so the d20 would clear the side of the t19 case. Oh, it's important to note that the t19 case was from a 2wd truck and I had to drill the missing holes on the rear of the case so that rear bearing t/c adaptor would mate up. It wasn't a situation of bad clocking, either. The case simply had some extra bumps on its side.
Click to expand...
 
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