Like any truck project is ever really complete...

I finally finished rebuilding my transfer case (Dana/Spicer 24).

I got the rebuild kit online and it worked well. One of the seals is a little thinner, but it will work just fine. I had to sleeve the input and output yoke shafts so it should stop marking it's territory.

I've only had an hour or two here and there to work on it so it took a bit.

No real issues, except I didn't press the outer output bearing on enough on the first pass and had to redo it.

Zero noise now and the shifts are firm and positive. Before the rebuild, it leaked, had sloppy shifts and rattled like a son of gun.

A much easier rebuild than I expected and actually fun to do. I almost hate to reinstall it and get it dirty..

I'll get some pics posted of the project in the next few days, but just wanted to share my progress.

I also got the engine cleaned up and painted. As soon as I get the clutch in, it will be ready to reinstall also.

Then it's just re-installing brake lines, transmission and drive shafts before putting the cab and front clip/hood back on. Once THAT's done, its on to the rewire and installing the interior.

I had an Oct 1 goal for completion, but I should have known with my schedule that wasn't going to happen.

As of now, I'm hoping to have it on the road before the first snow. That could be next week or spring knowing Kansas...

Parts on the bench (sure glad I had a manual to put it back together..)



Case getting Painted



Case Before Painting and final clean

 

awesome!
i would have messed that up....

 

Nice work Ill have to do that to both of mine sometime.

 

did you get a kit or parts and who did you get it from

 

I got the seals and bearings on Ebay; FORD DANA MODEL 24 Transfer Case Rebuild Kit Iron Case 2 Speed Gear Driven from Seller Acerl. It was 129.95 with free shipping.

The rebuild was pretty easy, but having the service manual was a big help. Keeping parts organized was important as well; the wrong bolt in the wrong place can hit a gear. Shop press was a must as well.

I'll say this - the assembled transfer case is HEAVY

Here is the completed Rebuild:





And a sneak peak at the engine about ready to go back in..

 

Looks great! So awesome when people actually post pics of what they're working on....

 

All 1960/65 FoMoCo engines were painted black. The valve cover(s) were painted specific colors as this is how FoMoCo identified engines sizes for garages/body shops.

1966: First year engines were painted Ford Corporate Blue, including the valve cover(s).

 

Don't know what to say about the color..

The block was blue when I pulled it from the truck

Plus, I like blue and red...

 

Wouldn't black & white be more apropos?

 

Lol
Don't think I didn't consider it for the truck itself

 

Beautiful job, let me know when I can bring my 223 and Spicer 24 up to Wichita for you to rebuild them.

Are you going to add a stiffner for your Spicer 24? I think some of the guys on this forum highly recommend it. Seems you can get a stiffner from a later model that will work.

What are you going to do for wheels? I am running the skinny 7 x 15 on black steel rims which look good and original for the flatbed but I do not think they would look good on a slick, the tires are pretty loud on the hiway but with ac and the windows closed, it is not too bad.

Have you decided on keeping or replacing the bed? I am thinking about parting out a 66 slick with a pretty solid bed sides, fenders, and front, the bed itself is great until you get up to the front, repairable. It has some great chrome and a heavy duty wrap around rear bumper.

By the way, please email me, I lost all my email contacts.

 

Not sure I want to tackle the 223 right now, but the Dana 24 would be a pleasure. You buy the kit & I'll rebuild it for you; I'm pretty sure I used up all my mistakes on mine and should be able to get it done in one try...

I've thought about adding the stiffener for the transfer case. I've seen it done with an NP205 but not the Dana 24. I'll have to do some research.

It wasn't until I got it back in the truck today that I realized how bad the bushings where; Have some on order and will get those replaced before I reinstall the drive shafts.

I plan on getting the clutch installed tomorrow and then will drop the engine back in, and then install the rebuilt transmission. Then it's drive shafts, putting the brake lines back on and finally the cab and clip..

Haven't decided on wheels tires yet but had a few ideas; thinking 16.5x10 wheels and 35's..

In terms of the bed, I'm going to try and salvage the original. It needs some work on the bed floor, new rear corners and some banging on the front left corner. No harm in trying and if I can't get it like I want, I'll see about my options.

If things go well, I hope to be ready to drop on the cab and clip by the end of the month. I have to go to a funeral on my days off next week (St. Louis) so won't have more than a couple of hours here and there until then.

Inch by inch...

 

Nice Work! When you get it done you will have to come buy the central and west car show on Friday nights.

 

I managed to get a few more things done today.

I got the clutch replaced and the housing back on; the engine and transmission came out of an F-600 and it has a 12" clutch. I got a clutch alignment tool from HF and it worked great. The one that came with the clutch had a WAY too big tip and pilot bearing.

I also managed to fix the loose shifter issue and got the shifter arm painted.

I think I'll re-install the brake lines next and then get on to the dreaded door seals. I want to get those done before I drop the cab back on.

My headers are due in on 10/14 so once those are installed I'll drop in the engine and transmission, re-install drive shafts and anything else that's easier with the cab off.

Then it's cab, steering gear, clutch re-connect, front clip, parking brakes, interior and re-wire.

Then it will be working out gremlins and on the road...

Oh.. after I get the dual exhaust made up.. and anything else I forgot..

 

You move fast do you have a helper? And then are you painting this baby