Ok, looks like the cylinder is the heat exchanger. I'm guessing that to remove it I just unbolt it and cap off the coolant line running to it?

 

Yea that'll work.

Maybe the 5 speed radiator in the 89 has some kind of plug in the system to completely delete the heat exchanger line?

 

I've come to a conclusion:

Pulling a manual out of the truck, no matter how rusty, is still easier than pulling a 518.

What a PITA! The coolant/heat exchange lines are messy, the linkages are crazy, everything is just a little harder to get to.

I stopped yesterday before actually unbolting the tranny from the engine. I assume I have to pull the bolts that hold the tc to the flywheel, then pull the bellhousing bolts. I had spilled so much fluid that I had to stop and clean up a bit...I was getting soaked (and I was even on a roller).

Oh well...getting close...once everything is out, I'm going to pop the new seals in the 205, clean the heck out of my truck and then start bolting it together.

 

How u gonna cut tHe hole in the floor?

 

I've been thinking about that a lot, actually.

My current plan, which can change if necessary, is to go to the donor truck and make a carboard template. A hole where the 4wd shifter comes out and a hole where the 360 shifter goes thru.

Then just move that cardboard over to the other truck, line it up and cut. I'm not sure if I'll use the jigsaw, sawzall or rotozip yet.

 

One thing... i've seen is that MT trucks have larger tunnels than AT trucks... might need a LOT more cutting.... Also maybe replace the rear main seal? while you right there

 

I haven't noticed anything different on the two tunnels. I'll have to take a look. The AT is a lot bigger than the MT, though...I'll tell you that much.

 

My tunnels were exactly the same. To cut my hole, I measured carefully and used the appropriate sized hole saw from the bottom up through then trimmed the floormat from above. Worked perfect, wear safety glasses though.

 

Ok, so today I pulled the clutch pedal and cylinder assembly.

I've got to tell you...if you haven't had the opportunity to work underneath the dashboard...it's really something.

And the cool thing about these old trucks...every bolt has a nut. Nope, one tool up there on the other side of the steering column and 14 wiring segments is not enough...two is much better.

The FSM has been invaluable so far in this project. The clutch cylinder behind the pedal, for example, uses a small plastic plug to keep it in position. Where it goes through the firewall, it has a half twist to it to lock it in, and this little tiny plastic pin holds it from turning, and thus from letter go.

You have to stand on your head to get to that pin, though.

Looking under the keeper, it looks like under the dash is really all set up for the clutch pedal assembly...other than the fact I used that big grommet to run the majority of my wires into the cab. DOH!

But she is coming along...ever so slowly...fighting tooth and nail.

 

i'm coming from what i saw with my own eyes the other day at crossys house. His manual tunnel is HUGE compared to mine(auto).

 

I know there's a 'that's what she said' joke in there somewhere.

 

Yea i think all the 4x4's were the same...and the 2wd 5spd tunnel is bigger than the 2wd auto tunnel. I think

 

So, a few good ol' boys headed down from upstate NY this morning in a 96 Powerstroke with 400k miles and a gooseneck trailer and picked up the donor truck. They stuck around long enough to help me get the automatic out of my truck, so they could take that with them.

...and then there was one.

 

congrats

 

Ha...thanks...little early for that, though...still have to make everything fit together and get the truck back on the road....lol...so I guess I'm about 1/2 way there...doh!