M1078 A1 transfer case

[Ronmar]

Unfortunately, in order for those roller bearings to get to the drain, they must pass thru the clutch, and there is not a lot of room for that to happen with the alternating stacked disks and center carrier… i would suspect some P6 case/cover damage

i think someone really miscalculated the force created by that center clutch disc carrier when the P6 is released coming out of 1st. That is when I think it is smacking that bearing. I really only see casual contact or perhaps small accelerations when the trans is shifting up thru the gears(that 2-3 shift can be kinda harsh). There just doesn’t appear to be anything else to accelerate the center carrier toward the rear and into that bearing. but it is heavy, so would not take much push to deliver considerable force…

The bearing appeared a little cheesy/light weight to me, but perhaps it coming apart in my hand when I started to pull it off has clouded my opinion of it…

 

[Skyhawk13205]

Unfortunately, in order for those roller bearings to get to the drain, they must pass thru the clutch, and there is not a lot of room for that to happen with the alternating stacked disks and center carrier… i would suspect some P6 case/cover damage

i think someone really miscalculated the force created by that center clutch disc carrier when the P6 is released coming out of mode. That is when I think it is smacking that bearing. I really only see casual contact or perhaps small accelerations when the trans is shifting up thru the gears(that 2-3 shift can be kinda harsh). There just doesn’t appear to be anything else to accelerate the center carrier toward the rear and into that bearing. but it is heavy, so would not take much push to deliver considerable force…

The bearing appeared a little cheesy/light weight to me, but perhaps it coming apart in my hand when I started to pull it off has clouded my opinion of it…

The bearing is held together by 3 crimps, not much to it. I am not sure a piece of plastic is much better, but maybe if the plastic breaks apart it won’t destroy the housing.

 

[Ronmar]

I suspect the bushing will better withstand the tap-tap-tapping from the clutch carrier. In the case of the roller, I believe the repeated impacts loosen/fail those crimps(appears to be what happened to mine). Once the cover pops off continued tapping with the cover no longer lined up properly causes the cover to break-up the internal composite bearing spacer/carrier, releasing the rollers…

 

[wandering neurons]

Copy, thx. Will check Monday morning

PERIPARTS GROUP155 48th Street, Brooklyn, NY 11232 United StatesPhone: 718-717-2524 • info@peri-parts.com • www.peri-parts.com

NO. P/N DESCRIPTION PRICE, USD BRAND
1 29545936 WASHER - THRUST $339.26 ALLISON

2 29537003 GASKET $44.29

 

[wandering neurons]

Also, regarding crossmembers. I’ve got the M1081 bed. Above/behind the C6 pack is the bed side panel storage bin. That
l need to be trimmed for the top of the clutch. Below/behind the pack is a tubular crossmember.
I have no issues cutting the storage bin to clear the top of the pack.
Will the lower tubular crossmember get in the way? If so, I may cut a section out and either sleeve and bolt or have the removed section welded back in place.

Thoughts?

 

[Ronmar]

It clears the round huck-bolted crossmember in the lower/main frame rail just fine…

 

[wandering neurons]

Oh fan-fscking-tastick. Thanks for that piece of good news!
Front driveshaft is out for new u-joints, trans filters replaced. Nothing apparent in the two filter screens. Will pull rear driveshaft for joints and use that extra space for the C6 fix.

It clears the round huck-bolted crossmember in the lower/main frame rail just fine…

 

[wandering neurons]

Pulled the rear driveshaft, cut a piece out of the storage tray rail, and pulled the C6 assembly. Removed the snap ring, lifted out the inner section with friction and steel plates. Other than the two metal races, the only thing left of the bearing was a few small pieces of metal and plastic in the housing. I carefully unstacked and examined the plates and steels. The bottom-most friction plate is worn unevenly, more on the outer edge than inner edge, on one side only. I’m thinking of flipping that friction plate over so the worn side is to the inside rather than outside. You can see some of that wear in the last picture.
Otherwise, I have no idea where the rest of the bearing pieces went. No sign of wear in the C6 housing, nothing in the bottom of the oil drain pans. The oil was pretty clean, a little darker than fresh oil, about like a gasoline engine oil change color.
I got a magnetic oil drain plug from NAPA and now I know why the long bolt was there, not the normal plug: the plug hole was stripped for the length of the drain plug. I cut about 1/3 off the bolt and put that back. I’ll get a magnet and JB Weld it on the end of the bolt later before refilling the units,
I’m hoping/praying that the last fluid change in the transmission/transfer case dumped the old pieces of C6 bearing as I’m seeing nothing. The filters, while dirty, don’t show signs of metal of plastic junk.
Army probably didn’t identify the problem before they DRMO’d the truck with about 10,000 miles. I’ve got about 21,000 now and no ugly feelings or indications from the transmission or transfer case.
My plan is to get the C6 replacement for the bearing, reassemble and drive for a little while, then check the magnetic plugs for junk without doing a full change. If they’re clean, make a sacrifice to the Allison gods. If there’s crud, do another flush.

You can see the notch in the tray

Back of the C6 section of the transfer case

On the bench before disassembly

Disassembled showing the unevenly work friction plate, the one I’m thinking of flipping before reassembly

 

[wandering neurons]

Replacement plastic bearing and gasket is now on order through a local Allison dealer - Smith Power Products in Sparks, NV. About $400 for the bearing, not so much for the gasket ($40-$60?). Overnight from Allison supply another $20.
Sigh. There goes some other toys I wanted to get for other vehicles. Like a winch for the Zombie Truck (the vehicle in my signature). Oh well, I can compete with the Government and just print some more, amiright?

Pulled the rear driveshaft, cut a piece out of the storage tray rail, and pulled the C6 assembly. Removed the snap ring, lifted out the inner section with friction and steel plates. Other than the two metal races, the only thing left of the bearing was a few small pieces of metal and plastic in the housing. I carefully unstacked and examined the plates and steels. The bottom-most friction plate is worn unevenly, more on the outer edge than inner edge, on one side only. I’m thinking of flipping that friction plate over so the worn side is to the inside rather than outside. You can see some of that wear in the last picture.
Otherwise, I have no idea where the rest of the bearing pieces went. No sign of wear in the C6 housing, nothing in the bottom of the oil drain pans. The oil was pretty clean, a little darker than fresh oil, about like a gasoline engine oil change color.
I got a magnetic oil drain plug from NAPA and now I know why the long bolt was there, not the normal plug: the plug hole was stripped for the length of the drain plug. I cut about 1/3 off the bolt and put that back. I’ll get a magnet and JB Weld it on the end of the bolt later before refilling the units,
I’m hoping/praying that the last fluid change in the transmission/transfer case dumped the old pieces of C6 bearing as I’m seeing nothing. The filters, while dirty, don’t show signs of metal of plastic junk.
Army probably didn’t identify the problem before they DRMO’d the truck with about 10,000 miles. I’ve got about 21,000 now and no ugly feelings or indications from the transmission or transfer case.
My plan is to get the C6 replacement for the bearing, reassemble and drive for a little while, then check the magnetic plugs for junk without doing a full change. If they’re clean, make a sacrifice to the Allison gods. If there’s crud, do another flush.

View attachment 963912 You can see the notch in the tray

View attachment 963913 Back of the C6 section of the transfer case

View attachment 963915 On the bench before disassembly

View attachment 963916 Disassembled showing the unevenly work friction plate, the one I’m thinking of flipping before reassembly

 

[aw113sgte]

Replacement plastic bearing and gasket is now on order through a local Allison dealer - Smith Power Products in Sparks, NV. About $400 for the bearing, not so much for the gasket ($40-$60?). Overnight from Allison supply another $20.
Sigh. There goes some other toys I wanted to get for other vehicles. Like a winch for the Zombie Truck (the vehicle in my signature). Oh well, I can compete with the Government and just print some more, amiright?

Well at least you'll feel like it's worth it when that little $370 ring of plastic arrives! (Still bitter...they made a huge error, offer the cheap composite part for free, feels like they are trying to recouperate all the engineering hours wasted by some incompetent engineer)

 

[wandering neurons]

Yeah, not happy it's a stupid-expensive part that went through several redesigns. And it didn't make it to the local shop as promised this morning!
I've looked at another thread that covers metal in the transmission/transfer case and seen where there's a strainer in a line from the transfer case to the scavenger pump. Guess what's being pulled to look for more metal...
Metal in Transfer Case post #40 (https://www.steelsoldiers.com/threa...eth-on-transfer-case-drain-plug.214636/page-2)

Well at least you'll feel like it's worth it when that little $370 ring of plastic arrives! (Still bitter...they made a huge error, offer the cheap composite part for free, feels like they are trying to recouperate all the engineering hours wasted by some incompetent engineer)

 

[Ronmar]

Oh i thought you had checked that strainer behind the fitting where the line leaves the trans to the scavenger pump.

 

[wandering neurons]

i remember seeing something about the strainer a whole back but chased down the info today. The thread had some good pics of what was found. Another project, but everything’s delayed while I help clear up a friends estate. Lots of old cars, nearly all Dodge products. And I’ve got to contract someone to get this to my house about 30 miles away. Hasn’t moved in about 15 years of more.

Oh i thought you had checked that strainer behind the fitting where the line leaves the trans to the scavenger pump.