D18 and T14 Build

Build Photos

I am trying the near impossible... to get the D18 to stop leaking. I will be replacing the bearings and seals in the D18 and just the seals in the T14.

BEFORE / AFTER

Here is a thread that I started regarding rebuild kits for the D18.

First thing I did was to strip everything down. Removed a ton of old RTV and had few issues with the nut holding the EBrake, the PO rounded all the edges so I had to take an air hammer to it.

After stripping everything down I used the gifts my wife got me for my birthday, a new parts tank and a sand blaster... Made sure not to blast any of the seal areas.

Once all the gunk cleaned and the blast media removed I wiped the parts down with alcohol and taped off all the seal areas and primed it black....

Next was the paint.....


Most important tool in my garage!

 

Must Haves

During this build I have added to my list of "must have" tools.

1) Factory Service Manual
2) Computer to access ECJ5.com
3) Block of wood
4) Glock pistol cleaning kit - used to clean bolt threads
5) Digital Camera to take pictures as you take stuff apart

 

Brake Job

D18 EBrake Job....

BEFORE and AFTER

 

Thanks for the detailed pics, I cant wait till winter to begin my rebuild

 

I am so glad I took detailed pics.... I am now putting it all back together and find myself saying.... "now where did this bolt go" and "how did that ebrake lever go in there"....

 

On the home stretch....

Got all the gears back in the case and time to measure the end play. I started by measuring the shims I took out of the tcase when I took it apart (.0063).

So I put new shims back in that measured the same and measured the end play.

It measured .0103, outside of the recommended tolerance and I have not coated the shims with copper sealant.

It will be a few days before I can work on it again but it looks like it will take a few more attempts.

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EDIT: picture of end play measurement updated.
All pictures can be found here.

 

Did you measure the endplay with the rear bearing cap on, or off? Did you take the rear bearing cap off for the picture?

 

I actually measured with the rear bearing cap and ebrake back plate on and torqued. PIC

That is the correct way, right?

 

I believe so. Looks great. I just pulled my D18 apart, hot tanked it, painted it, and am currently putting it back together, so I'm watching this with more than the usual interest. I'm using the WillysTech Dana 18 rebuild guide for reference.

 

No, you need to putt he yokes on and draw them up tight like there suppose to be. If you don't the endplay will change when you torque down the yokes.

 

Thanks for the help guys.

The case also came with a intermediate shaft conversion... Is there a proper torque setting for the castle nut on the intermediate shaft? I tightened it down until it started to impede the gears/bearings from turning freely and then just backed it off a bit. What is the "proper" way to tighten it down?

Intermediate Shaft
Pic 1
Pic 2
Pic 3

 

I got the yokes on and tested the end play. Once it was correct I sealed it all up and put it back together... AND IT IS DONE!!!

Here are the shims with the copper spay seal prior to assembly... Here it is after it is together (PIC).

EBrake
New Yoke and Final Assembly - Notice the open PTO, just waiting for my Warn OD.
Oil Cover