So unfortunately the transmission had to come back out due to an oil leak from the top cover. It has never leaked until now---so after running it and testing everything out, this turned out to be the only leak.

I took it back out and found barely any RTV sealant on anything; other than the PTO covers. I bought a gasket set for it and went thru and replaced all the seals and installed gaskets where there was just RTV (recommended by the service manual, LOL); unfortunately I could not get the yoke nut off--nothing big enough here to break loose 280 ft lbs, so I am going to have to wait to reinstall the trans until I can borrow a 3/4 impact and get the rear cover sealed up. Overall, the transmission looked good inside, no issues to speak of.




While I was contemplating working on the transmission, these showed up:





Decided to upgrade to the 13" clutch and flywheel from South Bend, to handle my future engine mods.

As of now, new clutch/flywheel is installed, along with the bellhousing, if all goes well with the rear yoke nut, trans will be back in next weekend.

 

Latest update; Trans is re-sealed, back in, sent the driveshaft out, had it balanced, replaced all u-joints, center bearing; she's running good. I drove it around the neighborhood last weekend, no hood, fenders, windshield, or doors, she ran great, really liking the feel of the South Bend clutch. Also repaired the ABS with a NOS module, got rid of the lights that have been on on the dash for 10 years. Turns out the HCU went bad back then and blew the integral fuse in the controller.

Next steps are to media blast the fenders, hood, doors, and cowl cover, install the new windshield, and get her ready for the trip to the body shop in May.

 

You will love that S.B clutch.
Excellent use of the spare bedroom. That is going to be one nice 1st gen when your done with it.

 

Very nice work! Reminds me a lot of a truck I had 17yrs ago except mine was a 360 auto. Other then that it looked identical, I loved that truck

 

Time for an update, the last month or so has been all small stuff, as I'm waiting on the sand blaster to get the hood, fenders, doors, and cowl panel done before bodywork can proceed.

Mostly I've been installing components, cleaning, etc etc.....I've started to restore all the bolts, screws, and nuts for the interior and body; first step, rust removal, then acid dip, then wash, then either black oxide coating, or zinc plating. They are coming out like new; you can see the before on the top, after on the bottom;



Today was the first batch, just have these to do yet;




Also, I tackled the lower shifter boot, which I have been searching for for 2 years, new has been discontinued for 15 years, every used one is torn out just like mine. The first picture is the best used one I could find, still torn. The original was missing nearly the entire center section of the boot. So, searching around, I found a Ford Mustang boot had a very similar design, so I ordered one;

Torn boot;



Old boot cut out of frame:



Mustang boot trimmed up and installed:



It will seal nicely once installed, and the upper shift boot will cover it up.

Other than that, this is about it until the body parts get blasted; hopefully soon.

 

Looking really nice

 

as usual great info and pics- can you please give us the Mustang boot part number. thanks- Crossy

 

The Ford number is 3R3Z*7277*AA; The original number comes with a metal ring, which you dont need; you can get them without the ring on ebay for $18.

 

Beautiful attention to detail! Makes me feel a bit spoiled having a 91.5 D250 Arizona 1st gen. No rust whatsoever compared to the work you performed. Great write up and thanks.

 

Got all the rest of the body parts back from the sand blasters. Saved myself hours of sanding (would feel like years)....Nice clean bare metal to work with. Time to start prepping them for bodywork/paint. Hoping to have her ready to head to the body shop here in a couple weeks.

 

Looks great, but I don't see why you had to sandblast it. The paint falls off on it's own

 

Right, another year and it would have done all the paint removal for me..

Now if only it would put itself back together......

 

 

Slightly understated, my friend....

 

Did anyone else notice this ???

The sign, then the clock on the wall ? It's quitting time, and he's working for beer.



What a life ?