Search results

I have never seen the OEM PTO configured for airshift. The issue with those PTO's is they have five shift positions, R-N-L-N-H. The airshift cylinders I am familiar with will only actuate R-N-F. Maybe someone else has figured it out.

Thanks, Will! (y) In those pics I had only dry fitted the bolts. I later tightened them down. I made sure to also spec out all the hardware I replaced on those mounts.

PTO Air Valve Plumbing: Starting up the truck, I let the air build. I engaged the PTO valve to WIND and checked for smooth rotation. Opening the vent fitting above the bull gear on the winch, I could see the gear was rotating in the WIND direction. This verified the air plumbing from the valve...

PTO Shaft: The span from u-joint centerline to u-joint center is 76 ¼”. An original one-piece drive shaft from the PTO to the winch input shaft will not work. The OEM transmission and PTO put that input shaft farther out toward the right frame. The new transmission is narrower at the bottom in...

PTO Operation (continued): I installed the Winch Operation Plate just forward of the valve with 1/8" pop rivets. I plumbed the air supply from the wet tank. The forward and reverse air lines were connected with slack. Once the winch drive shaft is hooked up, I can determine which line...

PTO Operation: The new PTO was equipped with an air shift but can also be lever shifted. I chose to use air shift rather than have to reconfigure all the lever shift linkage. A 4-way 3-position (neutral, forward, reverse) Air Valve was installed by custom cutting a hole in rear cab tunnel just...

PTO: As mentioned before, the OEM forward/reverse PTO is not compatible with this transmission. There are two reasons; (1) the drive gear is different and (2) the mounting on the new transmission is deeper. I was actually ramped up to do a hydraulic set-up ala an M939-series truck. However, the...

Gear Shift Lever: I found a Spicer shift lever on eBay that had the adapter collar compatible with the stub lever in the shift tower. However, it was bit longer and had a tighter angle than I needed. At the machine shop, I had it cut down in length to 18” and rethreaded at the tip to ½”-13. I...

Forward Cab Tunnel Modification: The new shift tower sits farther back on the 7-speed. The existing forward cab tunnel can be use by cutting a new 5” hole straight farther back as the two towers are on the same axis. I marked centerlines of the new shift to rear on rear cab tunnel and on the...

The original forward/reverse PTO is not compatible with the new transmission. I had planned to install an M939-series hydraulic system for the winch. I ran into design issues particularly with the hydraulic motor mounting. The motor would have to be mounted farther back in the frame as it will...

I installed the new 7-speed transmission. Due to its longer length, using a transmission jack in addition to a chain hoist makes the job much easier. I wired the clutch release fork lever up to avoid having the release bearing becoming disengaged from the release fork during installation. I...

Spare Tire/Toolbox Rack: Before the transfer case is reinstalled, the spare tire/toolbox rack must be lifted to a higher position. The bottom forward edge of the rack will interfere with the top of the transfer case in its new position. The fix is simple, but you will need a lifting device to...

Midships Driveshaft: The midships driveshaft was cut down 8” and rebalanced at a local driveshaft shop. I reinstalled the driveshaft with all new grade 8 hardware and two new 1710-series u-joints. You will notice the absence of original parking brake drum and actuation hardware.

Shift linkage bracket relocation: Located about equidistant between the transmission and transfer case is the T-shaped bracket spanning the frame width that supports the intermediate pivot points for both the transfer case and PTO shift linkages. This bracket must be moved back to clear the top...

Clutch Release Bearing: The 5-speed transmission was removed along with the clutch pressure plate and disc. The new transmission only comes in a 1 ½” input shaft for a push type clutch. This is limited by the input shaft bearing cover only available in a 1 ½” stem cap. So, the OEM 1 ¾” hub...

The forward fuel tank brackets each had minor modifications in order to accommodate the new transfer case mounting locations… Right: The original lower left bracket mounting hole (red circle) is now behind the transfer case bracket, so for ease of future maintenance I decided to no longer use...

Transfer case bracket relocation: The transfer case brackets were moved back a full 8”. I came to the measurement as follows: The ESO66 is exactly 35” in length from the clutch housing mounting face to where the end yoke washer seats on the output shaft. The end yoke adds 1.875” from the...

The left-side transfer case brackets require the removal of four rivets and two bolts (one on the rear toolbox/air tank bracket and one on the forward fuel tank bracket). My photo shows my custom installed M915 battery box frame bracket. The forward-most bolt is hidden behind the bracket. The...

The first hurdle in this project was to remove the fuel tanks, their mounting brackets, front and midships driveshafts, jackshaft and the transfer case. These are pretty straight forward tasks and are covered in the TM. If you haven’t done it before, be forewarned that that transfer case is a...

Preface: I started this project last year in early January. Due to some design changes and funding issues, it is technically not finished yet as of this posting. The last step, making the winch operational again is still in its final stages. I have researched viable alternatives to the Spicer...