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Technical Early Ford Quick Change Banjo Build

Discussion in 'The Hokey Ass Message Board' started by brsturges, Nov 4, 2019.

  1. GearheadsQCE
    Joined: Mar 23, 2011
    Posts: 2,498

    GearheadsQCE
    Member

    Everything I have seen on your car is first class. Sorry to see that second class rear end:p
    When you're ready to step up, I'm here!
     
  2. With a Winters V8 Quick change you don't need to notch the 32 Gas Tank.
     
    big duece likes this.
  3. brsturges
    Joined: Oct 22, 2008
    Posts: 828

    brsturges
    ALLIANCE MEMBER
    from Miami, FL

    Alright, time for the axle assembly. The only hiccup I encountered was the fit between the driver's side axle and the ring gear. The axle goes through the ring gear in the area circled in red in the photo below and rides on the area of the axle circled in red. The fit was a bit tight, so I found a socket that was the right size, wrapped some 500 grit sandpaper around it, and honed the opening in the ring gear ever so slightly. That did the trick.

    IMG_5196.jpg

    I got all my internal parts cleaned up and spread out ready for assembly.

    IMG_5192.jpg

    I greased up the passenger side axle and the passenger side of the differential carrier....

    IMG_5236.jpg

    And slid the passenger carrier half onto the passenger axle. I then clamped the axle down in a vise to hold it steady when the rest was assembled.

    IMG_5237.jpg

    Some more grease on the axle teeth and the spider gears...

    IMG_5238.jpg
    IMG_5240.jpg
    Then I fit the spider gears into the passenger side carrier half.

    IMG_5241.jpg

    I greased up the driver's side carrier half and installed it the same way it came off. Note the punch marks on each half (circled in yellow), which were made during disassembly. An important step I am told...

    IMG_5242.jpg
    IMG_5243.jpg

    The last remaining parts are the driver's side axle and the ring gear assembly.

    IMG_5244.jpg

    Those got greased up and went together nice and smoothly thanks to the quick hone job.
    IMG_5245.jpg
    IMG_5246.jpg

    Then that whole assembly can be bolted to the passenger side assembly that is secured in the vice.

    IMG_5247.jpg

    Threw some washers on, applied some loctite, and torqued them down.

    IMG_5248.jpg
    IMG_5249.jpg

    That's it for the axle assembly. Next post will be assembling the housings and shimming the quick change gears.
     
    kadillackid likes this.
  4. 19Fordy
    Joined: May 17, 2003
    Posts: 6,858

    19Fordy
    Member

    Thanks for posting your QC experience. Looking forward to the rest.
     
  5. brsturges
    Joined: Oct 22, 2008
    Posts: 828

    brsturges
    ALLIANCE MEMBER
    from Miami, FL

    On to the next step....

    Before final assembly, I finally installed the axle seals. These are the seals at the ends of the banjo housings and they can be tricky to get seated correctly. I used a 3 foot length of allthread and a few sockets to build a little tool to press them in.

    IMG_5477.jpg

    The spacing is very important here. You can see my socket held up to the end of the allthread to check to make sure I will be able to disassemble everything once it is pressed/pulled into place. The big socket on the right presses the red seal into place when pulled in with a nut on the end of the allthread shown in a few steps below. The black socket centers the assembly nicely in the axle housing end. The allthread needs to stick out far enough to get on nut on it with a strong enough spacer (I used another socket) to take the load.

    The assembly gets inserted in the axle housing. I did this with the axle standing up and elevated from the ground, but you can do this with it laying horizontal on the ground too. Probably would have been easier :rolleyes:

    IMG_5478.jpg

    If you measured correctly, you'll have some allthread sticking out the end of the housing.

    IMG_5479.jpg

    I then placed an appropriately sized socket over the allthread and tightened a nut to pull the seal into the housing. The vice grips on the other end ensure the allthread won't rotate.

    IMG_5480.jpg

    The axle seal is nicely in place without any damage. The picture makes it look uncentered but it is in fact centered perfectly.

    IMG_5481.jpg

    More to come...
     
  6. butch27
    Joined: Dec 10, 2004
    Posts: 2,827

    butch27
    Member

    Great work a little more than I did on mine.
     
  7. brsturges
    Joined: Oct 22, 2008
    Posts: 828

    brsturges
    ALLIANCE MEMBER
    from Miami, FL

    Thanks guys.

    The next step was prepping the center section. I changed my mind a bunch of times deciding whether to use studs and lock nuts (which came with the kit), studs and acorn nuts, or bolts to fasten the housings to the center section. I ended up deciding on studs and acorn nuts. That meant I needed shorter studs than what came with the kit. I got some set screws for the job. There are two holes on each side of the center section that go all the way through, so I used sealant on those to prevent any leaks.

    IMG_5418.jpg
    IMG_5422.jpg
    IMG_5425.JPG

    This next part is really where the engine stand comes in handy. I rotated the center section so that the passenger side is facing up. Again, I decided against using any sealant and just greased the mating surfaces lightly.

    IMG_5482.jpg
    I installed the gaskets/shims for the passenger side based on the test fitting discussed above.
    IMG_5483.jpg
    I greased the axle housing mating surface...
    IMG_5484.jpg
    And then torqued down the acorn nuts in a star pattern. The instructions said 25 foot pounds if memory serves...
    IMG_5486.jpg
    Then the center section can be rotated on the engine stand and the axle assembly can be inserted as shown.
    IMG_5198.jpg
    Repeat the same steps for the driver's side taking care to use the correct gaskets/shims and torque it down.
    IMG_5492.JPG
    Once I assembled it for the final time, I rechecked the carrier bearing preload and the backlash. All was good. The last step is shimming the helical quick change gears, which I'll cover in the next post.
     
    teach'm, Ur2slow and kadillackid like this.
  8. brsturges
    Joined: Oct 22, 2008
    Posts: 828

    brsturges
    ALLIANCE MEMBER
    from Miami, FL

    Sorry for the delay in wrapping up this build thread. Life got in the way a bit.

    Time to install the quick change gears and get them properly shimmed.

    When you opt for helical cut quick change gears, it is recommended that you use the shim kit to adjust the forward and aft play the gears have on their respective shafts. This is done with shims shown below.

    IMG_6101.jpg

    The shims come in .030, .045, and .060 thicknesses. The instructions that came with the set were straightforward, but did not address how exactly to measure the play.
    IMG_6103a.jpg
    IMG_6102.jpg

    Before we start shimming, the spacer needs to be installed on the lower shaft. That's part number SR3417/SR3416 in the diagram above and shown in with the green arrow below. It's a tight fit so maybe heat it up a bit and be prepared to tap it home. A large socket or pipe is helpful here.

    Spacer example.jpg

    I couldn't figure out the best way to measure for the right clearance. Bruce had a great suggestion, which was to over shim the gears, install the cover with the gasket (barely tightening down the cover) and use a feeler gauge to see how much gap you have. The first trick is getting the gap to be even from top and bottom. My clearances were slightly off when I used the same shims on both shafts. My top shaft needed a .060 and the bottom shaft needed a .045. That got me a uniform gap between the case and the cover. See the picture below of me using a feeler gauge.

    IMG_6105.jpg

    Some math is obviously involved here. If you have .025 of clearance between the case and the cover, you need to remove about .015 worth of shims. You are shooting for a clearance of .005 to .015.

    Once this setting is figured out, you can carefully torque down the cover and your quick change will be essentially all done. I still need to figure out how I will be venting mine, but for now, the project is complete. Hope this helped some of you get an overview of how this project goes. It was certainly a fun one and I am thrilled to have an early Ford style quick change rear set aside for my next project. Thanks for following along. And once again, thanks to @GearheadsQCE for selling a great product and providing even better technical support!

    Brad
     
    teach'm likes this.

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