Well, my new clutch disk came today, and I got started putting her back together. While I was waiting on UPS to show up, I finished the outside air scoop for the heater install. I was going to put it on facing the rear of the truck like someone suggested, I think it was gimpyrobb, not sure. Anyway, If I would have put it on backwards it would have hit the fender when I opened up the side panel, and the mounting holes were too close to the front lock, so I just installed it facing forward like they usually are. Then after that I took the metal cover off of my poor mans low air pressure idiot light to make it stand out more and look more like the NOS kits.
After the UPS guy came, I was getting started on the clutch when my brother showed up, he was on his way through the area on his way to Kentucky for work, so he stopped in to have me recharge his air conditioner in his car, since he had to replace the compressor last week. After that hour diversion I got back to the task at hand, I installed the pressure plate and clutch. I applied a little blue loc-tite to the bolts for the pressure plate and then torqued them to spec. If you read the things I ran into tearing it apart, you know they were loose....that's not happening again! After I had it installed and torqued down, I hooked up the transmission and started hoisting away. That was a major mother huncher to put back in. The alignment was perfect, but the damn PTO shaft at the top of the tranny was hitting the cross member between the transmission and the transfer case. It was hitting on the way out too, but taking it out is easy. Getting it back in when you can't go forward anymore and you still need to go forward about another 1/2 inch sucks!!! I finally got it past the cross member after fighting it and re-hitching it a few times, it took about 2 hours just to get the transmission back in place. After that everything else was a snap. I adjusted the clutch release arm to as close to 3 1/4 inches from the transmission flange as I could, then put the linkage back on and adjusted the pedal free play. When I put the jack-shaft back in on the transmission and transfer case I also used a little blue loc-tite on those bolts as well. I don't want them coming loose again either. The truck is buttoned back up, but it was getting close to dinner time, so I cleaned up my tools and tomorrow morning, I'll fill the tranny with oil and reinstall the passenger seat.
Before I can start it up, I have some wiring issues to tackle. While I was hooking everything back up, I glanced up at the starter and noticed the wiring harness coming down between the starter and the frame had some bare wires showing. The rubber coating is dry rotted and peeling apart. One of the wires is burned in two because it was touching a copper line in that area, I think it is for the horn, because it worked when I left Wisconsin, but it doesn't now. So I'll fix that as best as I can before I hook up the batteries again, I'll be sure to get some pictures for ya'll.
Then I can report on how everything works after I finish that stuff up.
