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Ok. I completed the swap on my 1978 F-250 Supercab. It now has a 4 speed NP435. The only catch is I am experiencing quite a bit of difficulty in the shifting. On startup everything seemed find. Then I noticed a little grind in 2nd gear. Now it is very difficult to shift into 1st, 2nd, and Reverse. I have adjusted almost all of the freeplay out of the linkage and can't figure out whether the problem is with the clutch, the linkage, or the tranny. Any advice?
Your pilot bearing might be dragging a little? While at rest and clutch engaged continuously, shift into 3rd or 4th, then move shifter into neutral. After a few seconds in neutral, try to engage 2nd. If it then wants to grind into 2nd, you've definitely got something dragging on the tranny input shaft(the clutch or the pilot bearing).
How much free-play do you have in the clutch pedal, measured from completely released to where you feel resistance? As I recall it should be about 1 1/2 inches, but look at a manual to verify that.
The extra thickness of a new clutch disc can also sometimes be too much for the clutch linkage to completely disengage. And there have been instances where the facing material is simply too thick (out of spec) and there's nothing to be done but replace the disc with a correct one.
As far as 1st and Reverse, it's a truck tranny, and they often tend to hang up a little, and that's normal. I even find I have to "double-clutch" at times in order to get the 1st and Reverse gears to line up and let me into gear.
Good Luck. Steve
I found out that the pressure plate was bad. I was cheap and did not replace it like I know I should have when I did the conversion. A few of the fingers were messed up not allowing the plate to disengage fully.