218 to 242 swap

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Re: 218 to 242 swap

Post by dilvoy » Mon Jun 14, 2010 9:09 am

If you have an engine with a one piece rear main seal, do you have to drop the oil pan to change it out?
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Re: 218 to 242 swap

Post by dilvoy » Mon Jun 14, 2010 9:21 am

I have a supposed 6.2 diesel engine that has the one piece rear main seal and it looks like you don't need to remove the oil pan to change out the crank seal.

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Re: 218 to 242 swap

Post by hummer4x4guy » Mon Jun 14, 2010 9:24 am

I think I might have to or I need to loosen up some bolts somewhere. I tried to replace it once before but I had no way to grasp the seal and pull it out. Couldnt even drill a hole into the seal to allow myself to slip something into that hole to yank it out with...
I can not visualize how things look in the back of there right now but once I get closer I will report back.
Ah now I see your photo George.. how does one grab the seal and yank it out?
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Re: 218 to 242 swap

Post by dilvoy » Mon Jun 14, 2010 10:46 am

Get a seal puller. There must be many different types, but one that you'll find at most auto parts stores has a flat handle that is about one foot long and has hardened two pronged hooked tip. The puller is used sort of how a crow bar is used. The hooke are hardend, but not unbreakable or unbendable so don't try and pull such a large seal from just one spot.
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Re: 218 to 242 swap

Post by Ozhumvee » Mon Jun 14, 2010 2:15 pm

6.2 has two piece rear main seal, 6.5 has one piece seal, can't help with the depth but I'd imagine there is a shoulder to sit it against.
You may have to just cut the nut & stud that you can't undo.
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Re: 218 to 242 swap

Post by hummer4x4guy » Mon Jun 14, 2010 2:25 pm

Well
I finally got that last bolt out. I ground it off on one side of the nut then was able to use a punch to simply smack it off the threaded stud towards the otherside I couldnt get to with the grinder.
I got the tranny off and out of the way then got the flex plate off which is gona need to be replaced.. one section is worn out really bad and it does cause it to grind once in a while. The output seal looks really good and dry. Not to mention all the extra sealant I gooped up around it and the outside engine part. So I suppose I will leave it alone.
I will take a pic of it later on to show what it looks like vs what Georges looks like tho its the same but just for the heck of posting photos.
Plus a shot of the new and old tcase next to each other and the driveshafts and stuff.
All in all I about at the half way point now.. just need to put the new stuff back in.
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Re: 218 to 242 swap

Post by hummer4x4guy » Mon Jun 28, 2010 12:57 pm

DONE!
And here are some tips and tricks I learned along the way.

If you need to remove the rear main seal (the one just behind the flex plate) of which mine is a one piece but engine is a 6.2 99% sure. I drilled a lil hole somewhere in the middle of the seal. Then screwed in a drywall screw or whatever is handy and grabed it with some pliers and just pryed it out.

Don't fill your tcase untill it is in and your driveshafts are installed or you might over fill it on the ground and it will just leak allllllll over.

Drain the transmission.

It ISNT lighter then a 218.... *looking towards Brad*... perhaps on a scale it is but not when you try and bench press it in. Use a transmission jack.

You will have to remove the old parking brake rotor for the new rear drive shaft to fit so dont even try putting it back on.

Remember which side of the flexplate faces the engine it makes a difference. Luckily I remembered this from the last time I had it off.

Thats about it guys. The truck runs freaking awesomely. I don't know if running an old tcase can cause a truck to seem doggish vs a newer one but I sure love it.!
Joel
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Re: 218 to 242 swap

Post by jwaller » Mon Jun 28, 2010 1:11 pm

so the 242 bolted right up to the TH400? no problems?

did you reuse the original front shaft?

you had to change the rear one for a slip yoke.

is it smaller?

same linkage?
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Re: 218 to 242 swap

Post by hummer4x4guy » Mon Jun 28, 2010 1:21 pm

Yes in the "kit" you get a new rear driveshaft and a new rear portion of the front driveshaft. It isnt much different in length tho and I would be willing to bet you could get away with using the old original. But the rear one does need to be changed.
Fit right on no problem at all the 6 studs are all in the same location.
Its a lil smaller but not by a large amount in my opnion and the linkage was all the same. THO I did seem to notice that it looked like the 2 rubber lines that goto the cooling loop are a lil bit short and could use an extra 1/2 inch in length and one of the lines is rather close to the shift linkage also and it will rub I believe if in low.
So those are things I will have to try and figure out or find it more from someone else on here...
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Re: 218 to 242 swap

Post by jwaller » Mon Jun 28, 2010 1:44 pm

awesome, all great info, where did the pics of it all go?
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Re: 218 to 242 swap

Post by hummer4x4guy » Mon Jun 28, 2010 2:55 pm

It was such a dirty greasy job I didnt want to bring the camera into it. I was also in a hurry to finish it up.
I can take a few pics next time I get under the truck tho. Another thing I forgot to add is the vent hook up on the tcase is different. You need a two piece to get the 90 degree vs the old one piece 90 degree fitting.
Joel
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Re: 218 to 242 swap

Post by Ted Gates » Tue Jun 29, 2010 3:57 am

Just to add to it for everyone's information-

6.2 w/3 spd w/242 tcase:
Rear propellor with slip yoke is 28-13/16" from outside u-joint housings end to end, Joel has part numbers.

Front propellor (rear half) is 31-11/16" from outside u-joint housings end to end

I highly recommend doing this with the tub off ;-)

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Re: 218 to 242 swap

Post by hummer4x4guy » Tue Jun 29, 2010 4:23 am

Most jobs are easier with the tub off *rolling eyes*
Funniest thing said while putting in the new tcase was by Ted with the phrase "my meat paw". Still funny today. I DID take a few side by side photos of the new/old tcase and the driveshafts.
I will post em in here shortly.
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Re: 218 to 242 swap

Post by hummer4x4guy » Wed Jun 30, 2010 10:53 am

Image
As you can see there isnt much of a difference at all in the length of the new part of the shaft I got. But it was new and shiney so I put it on. Yes you need to remove the grease fitting for them to come apart but its still a good solid pull it needs.

Image

Older t-cases like it on top.
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Re: 218 to 242 swap

Post by hummer4x4guy » Wed Jun 30, 2010 2:03 pm

More photos from down under... no not Australia!

Image

Image

Image
As you can see in this shot the linkage arm is touching the steel line. I will need to make an adjustment on this so they do not rub.


Image

Image

Image
Joel
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