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Topic Summary

Posted by: johnrb3b
« on: April 18, 2013, 09:26:44 AM »

Quote
... but I'd rather send it back to Herm next winter when I can't drive anyways instead of ruining the next month of good driving.
That's how I handled my problem.
My solution with Herm actually took two years because I didn't want to take the Jeep down during the summer. He had no problem with that.
Just keep in touch with him so he knows that's what you're doing. He'll understand that you're wanting to drive it while you can and fix it in the winter.
I have nothing but good things to say about Herm and his support.

Posted by: garage gnome
« on: April 17, 2013, 10:12:57 AM »

I got to drive mine the first time on Monday and I noticed that the new bronze shift fork stopped the grinding. With the old aluminum one, it would grind a bit. And it feels more positive when shifting into OD. Maybe you could check you fork to see how tightly is fits on the shaft? If it has movement, I could see that being a problem.
Posted by: Ryan_M
« on: April 17, 2013, 10:05:48 AM »

Shims and adjustable screw cap have arrived from Herm, are installed, and roughly 50 miles put on the Jeep. With the screw cap too tight, it shifts between OD and DD very hard and grinds loudly, especially going in to DD. Once in DD, it seems to stay there as it should.

If I back off the adjustable screw it shifts much more smoothly but is back to its old trick of popping out of DD under any sort of load. If I set the screw adjustment somewhere in between, it'll grind AND pop of of DD. Not exactly the fix I was hoping for.

Herm is suggesting I send the entire rear part of the OD unit back so he can inspect. �I think I'd rather pull out one of my own teeth than disassemble this thing again (I've done it 4x now already) and then be down for however many weeks it takes for turn-around time and maybe a solution, maybe not. He also mentioned it could be the end play in the transmission shaft but I don't think that is the issue. I'm leaning towards just holding it in DD when needed as I spend most of the time in OD anyways. Still not right but I'd rather send it back to Herm next winter when I can't drive anyways instead of ruining the next month of good driving.

Has anyone else who installed the shims and adjustable screw cap had a similar problem, and a better solution?
Posted by: garage gnome
« on: April 07, 2013, 06:51:12 PM »

Let us know!
Posted by: Ryan_M
« on: April 07, 2013, 03:02:02 PM »

235 miles logged since the OD install and it still pops out of direct drive. It is absolutely fabulous in all other aspects though. What a difference between cruising between at 40mph and cruising at 50mph! I drove 140 miles last weekend like it was nothing. The motor certainly appreciates the gearing upgrade too - it's so quiet that it now allows me to hear all kinds of other problems in the drivetrain that would have otherwise gone blissfully unnoticed. � :-/

Herm is going to be sending out some magical parts that will hopefully remedy the direct drive issue. I'll update again once I have them in.

Posted by: garage gnome
« on: March 27, 2013, 07:44:25 AM »

Keep us updated Ryan. It will be helpful to know how it is fixed for future reference.
Posted by: Ryan_M
« on: March 27, 2013, 07:18:43 AM »

OD is installed and trim pieces buttoned up. A couple suggestions I would make to anyone else who installs one:

1. Attach shift lever rod to OD shift rail BEFORE installing OD unit. Doing so after the fact is nearly impossible unless you have 6-jointed fingers.

2. Shift stick is made for generic applications and may need some bending to fit properly. Test fit and bend BEFORE making it all pretty with 6 coats of paint and clear coat. None of that holds up well to the extreme heat of a MAPP gas torch.

After speaking with Herm, he thinks the reason I am popping out of direct drive is that a synchro is stuck. Apparently this can happen if the unit is shifted before being driven around, which is what I did. The OD unit arrives pretty well greased up to keep components from falling out and may be what's causing the problem now. He states that the synchro will likely free up after a thorough workout. Since the roads here are still encrusted with salt it will be awhile before I can put many miles on it. If I still have problems I'll probably be asking him for some shims as this seems to be the standard fix.
Posted by: johnrb3b
« on: March 26, 2013, 10:43:01 AM »

Quote
I've been doing some research and the issue I'm having with the OD popping out of direct drive is not entirely uncommon. I'm still not sure what the exact fix will be but I'm pretty sure Herm will have a solution for me. He seemed to get everyone else straightened out.
Yes, he will.
Mine was doing that too. He sent me some shims to correct the problem. Hasn't popped out in over two years now.
Posted by: garage gnome
« on: March 24, 2013, 09:40:07 AM »

I fixed it and I see why it needs to be the other way. It prevents the nut from backing out. Appearently, it doesn't make much of a difference though as I have tested it for 3 years now. ;D
Posted by: garage gnome
« on: March 24, 2013, 07:53:19 AM »

I'll flip mine around.
Posted by: F Bill
« on: March 23, 2013, 11:12:53 PM »

My OD had the tabs in, not out, and I can't see how it would lock that nut behind it with the tab out. I ruined mine as I didn't realize it wasn't the actual nut at the time I opened mine up , and tried to spin it out with the impact.. Bad move!! I might be able to save it but....I'd rather have a new one.
Posted by: Ryan_M
« on: March 23, 2013, 09:11:17 PM »

Quote
Yep, mine is opposite of yours! Good catch. I don't know how much of a difference it makes though. Do the instructions specifically say which way it goes? I do not know where mine are atm.

Although it does not specify in words which way it goes, Herm's instructions have that exact pic as the visual aid. Seems like it would be the right way as it "locks" everything together. At least now we know it doesn't make a huge difference either way, as you have proven.

I've been doing some research and the issue I'm having with the OD popping out of direct drive is not entirely uncommon. I'm still not sure what the exact fix will be but I'm pretty sure Herm will have a solution for me. He seemed to get everyone else straightened out.
Posted by: garage gnome
« on: March 23, 2013, 09:04:17 PM »

Yep, mine is opposite of yours! Good catch. I don't know how much of a difference it makes though. Do the instructions specifically say which way it goes? I do not know where mine are atm.
Posted by: garage gnome
« on: March 23, 2013, 08:23:11 PM »

I will check that out. It it apart right now, so I can easily see.

To bend the shift lever, put the square block in the vise and bed it from there. It doesn't mark up your lever that way.  ;) Good move on not cutting the cover yet. That is what I did too.
Posted by: Ryan_M
« on: March 23, 2013, 08:15:55 PM »

It is supposedly one of Herm's new homebrew OD's, not a rebuild. I will mess around with it some more and see if I can make any sense of it. I have not yet cut or installed the tranny cover. I want to make sure everything is in its final position before I break out the grinder again.

Here's what I'm referring to about your lock washer. Could be just the way I'm looking at it