The General

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Nikkormat
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Location: Salt Lake City

Re: The General

Post by Nikkormat »

Bummer Dude! I'll keep an eye out for good Q Trac's.
Gabe, "reformed" Jeep hoarder.
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ktrosper
Posts: 50
Joined: Tue Nov 26, 2013 2:11 pm
Location: Ft. Collins, CO

Re: The General

Post by ktrosper »

TH400 Teardown and inspection:

1st things first.. I'm too old to be breakin my back working on this thing while it sits on the floor :)
Welded up a tranny clamp out of spare steel I had laying around. I can spin it every which way now as I work to rebuild it..
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Tear down was easy enough. No special tools required (thin walled 12 point 3/8 in. socket is needed at one point but I thinned the walls of a regular one with my bench grinder) and plenty of youtube resources available..

empty housing:
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TH400 guts:
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The "Oh Crap!" findings..

Busted rear band:
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Thrust needle bearing totally disintegrated and a baggie containing the hardened steel bearings that were laying around in the case:
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Friction plates are also totally worn but the steel and everything else looks ok.. A few dings in the planetary gears, probably from the bearings getting caught in 'em.. I'm not going to replace them - too expensive.

So I've ordered:
Overhaul kit "less steel" ..
Bushing kit - what the hell. For 20 bucks I'll press in new bearings everywhere.
Thrust bearing kit..

Will update once it's back together.
"The General"
'79 Jeep J-20 | 360 | TH400 | BW 1339 | D44 (3.73) | D60-3 (3.73) | Stock Suspension | 33" Tires
Build Thread:http://www.fsjnetwork.com/forum/viewtop ... 12&t=11420
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ktrosper
Posts: 50
Joined: Tue Nov 26, 2013 2:11 pm
Location: Ft. Collins, CO

Re: The General

Post by ktrosper »

Nikkormat wrote:Bummer Dude! I'll keep an eye out for good Q Trac's.
Thanks Nik. I got a guy in Cali who might have a new bearing for me. I'm keeping my fingers crossed.
"The General"
'79 Jeep J-20 | 360 | TH400 | BW 1339 | D44 (3.73) | D60-3 (3.73) | Stock Suspension | 33" Tires
Build Thread:http://www.fsjnetwork.com/forum/viewtop ... 12&t=11420
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ktrosper
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Joined: Tue Nov 26, 2013 2:11 pm
Location: Ft. Collins, CO

Re: The General

Post by ktrosper »

Engine Machining done..

Got the block, heads, crank, pistons/rods back.

Block:
cleaned and mic'd.
The block was already bored .040 in. over - it's been rebuilt a couple of times probably.
Cylinder bores were all perfectly healthy and simply needed a hone.
Cam bearings pressed in.

Heads:
cleaned and checked for warpage.
Intake valves were shot - had to replace them.
Exhaust valves were ok.
Valve stem guides were all out of spec and newbies were pressed in.
Basic valve job.

Crank:
mic'd and polished.

Pistons:
cleaned/mic'd/inspected
honed crank end

Had them order my rebuild kit and crank bearings..

I was trying to keep machining costs down to a min. I should have done the valve job myself... I've done it several times with my dad and it ain't that hard. Would have saved me $155. Oh well :(

Done at AMS here in Ft. Collins, CO.
Good guys to work with. Pricing fair? I dunno - been 25 years since I had machining done..
Labor total: $540
Parts total: $415
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Next step:
Get Cam/lifters ordered..
"The General"
'79 Jeep J-20 | 360 | TH400 | BW 1339 | D44 (3.73) | D60-3 (3.73) | Stock Suspension | 33" Tires
Build Thread:http://www.fsjnetwork.com/forum/viewtop ... 12&t=11420
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ktrosper
Posts: 50
Joined: Tue Nov 26, 2013 2:11 pm
Location: Ft. Collins, CO

Re: The General

Post by ktrosper »

Front axle work:

Bought some perches a while back from Tad for the SOA conversion I'll be doing. I figured now was a probably a good time to get them welded on - before pushing in the new seals. I followed his instructions and they turned out great.
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Next step seals, thrust washers and reassembly... Up to the knuckles, anyway. Got some flat tops I need machined. So I'll send those out this week hopefully.
"The General"
'79 Jeep J-20 | 360 | TH400 | BW 1339 | D44 (3.73) | D60-3 (3.73) | Stock Suspension | 33" Tires
Build Thread:http://www.fsjnetwork.com/forum/viewtop ... 12&t=11420
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ktrosper
Posts: 50
Joined: Tue Nov 26, 2013 2:11 pm
Location: Ft. Collins, CO

Re: The General

Post by ktrosper »

BW 1339 QuadraTrac done (for now):

I think I may have found the last 63mm bearing on the planet.. I installed it and finished assembling the QT. It won't be "E drive" capable, as the gear was torqued off the differential end cap. I'll restore that capability sometime down the road after I gather the necessary parts.
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Just needs a bit of "QT Juice" and it'll be ready for installation once the truck is ready.
"The General"
'79 Jeep J-20 | 360 | TH400 | BW 1339 | D44 (3.73) | D60-3 (3.73) | Stock Suspension | 33" Tires
Build Thread:http://www.fsjnetwork.com/forum/viewtop ... 12&t=11420
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ktrosper
Posts: 50
Joined: Tue Nov 26, 2013 2:11 pm
Location: Ft. Collins, CO

Re: The General

Post by ktrosper »

TH400 good to go..
Rebuilt this baby step by step with this youtuber: https://youtu.be/_TMFibSiwVw

Bought this kit on ebay for $170: "TH400 3L80 Turbo 400 Performance Transmission Less Steel Kit Stage 4"
As you can see it's got all seals/gaskets, bushings, thrust washers, filter, front/rear bands, frictions and adjustable modulator..
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Additionally I bought a thrust bearing kit (one of mine had disintegrated) from ebay for $24: "TH400 4l80E Torrington Thrust Bearing Kit w / Races - AC Delco - 3 Bearing Set"
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Had to replace the plastic accumulator piston (it was TOTALLY broken) from Amazon for $12: "GM TH400 Turbo 400 Transmission Front Accumulator Piston - Aluminum"
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Like an idiot, I must have tossed the metal valve body separator plate.. Gave me a good excuse to buy a shift kit to fix some of the common issues with the TH400. Got it on ebay for $19: "Transmission Shift Kit TransGo TH 400 65-up (SK 400)"
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Total cost: $225

She looks good.. Hope she WORKS good!!! I'll store it until the truck is ready for it :)
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"The General"
'79 Jeep J-20 | 360 | TH400 | BW 1339 | D44 (3.73) | D60-3 (3.73) | Stock Suspension | 33" Tires
Build Thread:http://www.fsjnetwork.com/forum/viewtop ... 12&t=11420
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ktrosper
Posts: 50
Joined: Tue Nov 26, 2013 2:11 pm
Location: Ft. Collins, CO

Re: The General

Post by ktrosper »

While I'm at it...
Those evil words struck again this past week :)

The frame needs stripped and painted if it's gonna last another 40 years..
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The cab needs a lot of sheet metal work - floors and firewall mainly..
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"The General"
'79 Jeep J-20 | 360 | TH400 | BW 1339 | D44 (3.73) | D60-3 (3.73) | Stock Suspension | 33" Tires
Build Thread:http://www.fsjnetwork.com/forum/viewtop ... 12&t=11420
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ToolShed
Posts: 47
Joined: Tue Jan 03, 2017 8:14 pm

Re: The General

Post by ToolShed »

Looking good! Going to bookmark that YouTube video too. Thanks!
Jim

78 Cherokee Chief W/T 360 4V TH400 D20
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Greenmachine
Posts: 259
Joined: Fri Nov 07, 2014 8:59 pm
Location: Maryville TN

Re: The General

Post by Greenmachine »

Looks like a great build. I'm getting ready to rebuild an engine myself so I'm gonna watch this one close...
1975 Cherokee S factory 360,t-18, 4" hellcreek, slot mags 33" bfg's, performer intake, and Fitech fuel injection.
1980 J10 304, 5 spd, 4" Superlift, 4.88 Gears, 35" Maxxis Big Horns
1961 fc-150 fishing truck (on hold)

Former Air Cav
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ktrosper
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Joined: Tue Nov 26, 2013 2:11 pm
Location: Ft. Collins, CO

Re: The General

Post by ktrosper »

Thanks. I'm looking forward to it :)
I'll update as we go.. It's been damn near 30 years since I've done this so I'll be following Brian and Michelle Johnsons build book more or less. Probably turn out to be the best 10 bucks I ever spent ;)
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And look what showed up on my doorstep this morning!! :D
Freshly ground cam, new springs and lifters..
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"The General"
'79 Jeep J-20 | 360 | TH400 | BW 1339 | D44 (3.73) | D60-3 (3.73) | Stock Suspension | 33" Tires
Build Thread:http://www.fsjnetwork.com/forum/viewtop ... 12&t=11420
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ktrosper
Posts: 50
Joined: Tue Nov 26, 2013 2:11 pm
Location: Ft. Collins, CO

Re: The General

Post by ktrosper »

More front axle work..
I was reassembling her and snapped the damn pinion shaft when I was torqueing it down. Oops!
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So.. I kinda had it on my radar to change my axle gearing ratio in the future, as I'll be running 35s or 36s.. I pulled the trigger on a "thick" 4.30 ring and pinion. Came out of a Rodeo I think..
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Many good vids out there on how to set em up..
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I don't have any special tools outside of my basic micrometer... So it took a while but a shim pack and a bit of trial and error got everything within spec (pinion depth, pinion preload and backlash).
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Got her buttoned up and a new tag etched :)
"The General"
'79 Jeep J-20 | 360 | TH400 | BW 1339 | D44 (3.73) | D60-3 (3.73) | Stock Suspension | 33" Tires
Build Thread:http://www.fsjnetwork.com/forum/viewtop ... 12&t=11420
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ToolShed
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Re: The General

Post by ToolShed »

Damn!! Did you accidentally on purpose break it? My wife would probably accuse me of that lol
Jim

78 Cherokee Chief W/T 360 4V TH400 D20
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ktrosper
Posts: 50
Joined: Tue Nov 26, 2013 2:11 pm
Location: Ft. Collins, CO

Re: The General

Post by ktrosper »

HAHA! I might have ;)
"The General"
'79 Jeep J-20 | 360 | TH400 | BW 1339 | D44 (3.73) | D60-3 (3.73) | Stock Suspension | 33" Tires
Build Thread:http://www.fsjnetwork.com/forum/viewtop ... 12&t=11420
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ktrosper
Posts: 50
Joined: Tue Nov 26, 2013 2:11 pm
Location: Ft. Collins, CO

Re: The General

Post by ktrosper »

Knuckle work:
I'm swapping out the old knuckles for flat-tops while the front axle is torn down.. As you know, this will allow me to move forward with the high-steer conversion. Lots of research done here on these boards and Mr. N's Dana 44 Knuckle site for casting numbers and compatibility: http://77cj.littlekeylime.com/flatop_knucles.html

Cleaned up, assembled and painted:
Image

knuckles (ebay): $120
passenger side knuckle machining (local): $30
beefy 1.25" arms (ebay): $135
ball joints: $35
total: $350ish
"The General"
'79 Jeep J-20 | 360 | TH400 | BW 1339 | D44 (3.73) | D60-3 (3.73) | Stock Suspension | 33" Tires
Build Thread:http://www.fsjnetwork.com/forum/viewtop ... 12&t=11420

Charles Kline
Posts: 717
Joined: Thu Aug 06, 2015 8:00 am
Location: Golden, Co

Re: The General

Post by Charles Kline »

ktrosper wrote:TH400 good to go..
Rebuilt this baby step by step with this youtuber: https://youtu.be/_TMFibSiwVw
I like that guys videos, I ended up watching the whole Javelin series. His brother Paul has some funny stories.


Funny that he got his 401 and TH400 out of a Cherokee or Wagoneer.

One thing I noticed is on Part 2 @ 23:52 that metal gasket for the kickdown is only included to be used on the old style kickdown, Its not necessary with the newer solenoid. (Not that I think its hurts anything to use it)

Image
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ktrosper
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Joined: Tue Nov 26, 2013 2:11 pm
Location: Ft. Collins, CO

Re: The General

Post by ktrosper »

Interesting... I did toss that new metal gasket in- of course I reused my old solenoid. I'll have to keep that in mind in case I get some strange behavior.
"The General"
'79 Jeep J-20 | 360 | TH400 | BW 1339 | D44 (3.73) | D60-3 (3.73) | Stock Suspension | 33" Tires
Build Thread:http://www.fsjnetwork.com/forum/viewtop ... 12&t=11420

Charles Kline
Posts: 717
Joined: Thu Aug 06, 2015 8:00 am
Location: Golden, Co

Re: The General

Post by Charles Kline »

Also, it's awesome to see another great FSJ being saved in Colorado!!

We need to have a big get together soon.


-Charles
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ktrosper
Posts: 50
Joined: Tue Nov 26, 2013 2:11 pm
Location: Ft. Collins, CO

Re: The General

Post by ktrosper »

Thanks Charles. Fun stuff. So glad I've finally got the time and few extra bucks to get it done!
We'll be on family vacation while Ouray '17 is going on, so that's outta the question this year :( We should consider a late summer BBQ as a send off for Nikkormat (Gabe?) as he heads off to college though...

More axle work:
Had a few minutes to get these knuckles attached and everything torqued to specs.
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I hope this week I can have this D44 finished so I can turn my sights to the 360 build.
"The General"
'79 Jeep J-20 | 360 | TH400 | BW 1339 | D44 (3.73) | D60-3 (3.73) | Stock Suspension | 33" Tires
Build Thread:http://www.fsjnetwork.com/forum/viewtop ... 12&t=11420

Mtnmax
Posts: 13
Joined: Fri Aug 11, 2017 6:04 am

Re: The General

Post by Mtnmax »

Hello!!

I just picked up a 79 Cherokee and I will be following in your footsteps soon. I'm curious about your recent progress. I'm also in Colorado, Grand Lake.

Thanks!
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