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Simple engine swap turns ugly!

Posted: Tue Oct 13, 2020 4:23 pm
by Chuck W.
Tony brought his mule and his new 2AO-42 crate engine down today for a simple engine swap. As I was getting the old engine ready to come out, I pulled the bell housing plug and 2-3 gallons of transaxle oil came out! So, the axle shaft seals are shot and the rear axle ring gear and the right axle housing has to come off since the seal is installed from the ring gear side. All three of the seals were hard and leaking and will be replaced. I won't start the engine changeover until the axle housing is back together.

The lift paid for it's self again! No sore back!
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I got lucky and all the right frame tube bolts came loose, which is really unusual for me!
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Everything came apart much better than I expected, and all the bearings, races and gears are in excellent shape, so seals and gaskets are all that will be needed.
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The CJ3B project had to move under the carport until this mule is finished.
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Re: Simple engine swap turns ugly!

Posted: Tue Oct 13, 2020 6:32 pm
by GUNNUT in Iowa
It appears to me (at least in the first three photos) that you may have your anti-gravity device turned up too high.

:lol:

Re: Simple engine swap turns ugly!

Posted: Wed Oct 14, 2020 3:19 pm
by Chuck W.
More progress today, mostly cleaning. I removed the right frame tube completely and used a scotch bright wheel on a 3 foot extension to knock all the rust off the inside of the tube then treated it with some Loctite® Extend Rust Neutralizer.
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Then I started stripping the 2AO-42 engine of all the un-needed parts.
Fresh out of the crate
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I need to make the one on the right look like the one on the left
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Looks naked! Still need to remove the old oil pan and lines.
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Pile of un-needed parts from the 2AO engine.
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Re: Simple engine swap turns ugly!

Posted: Thu Oct 15, 2020 8:34 pm
by Chuck W.
Axle seals have been replaced and the rear axle re-assembled and filled with oil.
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No leaks so far!
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None of the adapters in my seal driver set fit the new seals very well, so I turned some custom ones that are a perfect fit.
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I also got most of the parts off of the donor motor.

Re: Simple engine swap turns ugly!

Posted: Sat Oct 17, 2020 3:04 pm
by Chuck W.
Engine swap moving along.
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Re: Simple engine swap turns ugly!

Posted: Tue Oct 20, 2020 3:30 pm
by Auto Shop teacher
Thanks for all the photos Chuck, that was quite some 'detour' you needed to make, but the mule is all the better for it. Was the clutch disc soaked in 90#?

Looks like your getting your money's worth of that vehicle lift you bought a few years ago. :-)

Re: Simple engine swap turns ugly!

Posted: Tue Oct 20, 2020 3:33 pm
by Auto Shop teacher
forgot to ask, how did you support the mule with the right frame tube out for repair?

Re: Simple engine swap turns ugly!

Posted: Tue Oct 20, 2020 8:31 pm
by Chuck W.
Put the engine back in this morning.
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Fired and ran it this afternoon. Still have a few things to finish up.
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Yes, the clutch disk was soaked with 90 wt and the inside of the flywheel housing was a mess. I replaced the disk and will have the old one relined and put back in my stock.
forgot to ask, how did you support the mule with the right frame tube out for repair?
I had jack stands under both sides of the transaxle and the engine hoist hooked to the back of the deck!
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Re: Simple engine swap turns ugly!

Posted: Wed Oct 21, 2020 12:37 pm
by Chuck W.
finished!
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Re: Simple engine swap turns ugly!

Posted: Fri Oct 23, 2020 10:14 am
by abbylind
Nice work! BTW how big is your shop?

Re: Simple engine swap turns ugly!

Posted: Sat Oct 24, 2020 3:04 pm
by Chuck W.
It's not big, it's very small!
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I have a mule, and M100 trailer, a CJ3B and an M38, plus my tools in there, so it is very full!

Re: Simple engine swap turns ugly!

Posted: Sun Nov 01, 2020 1:39 pm
by abbylind
Looks like its about 20 X 20?
Im looking to build a shop at my new house...probably end up 12 X 18....

Re: Simple engine swap turns ugly!

Posted: Tue Nov 03, 2020 3:43 pm
by Chuck W.
20' x 28', actually.

Re: Simple engine swap turns ugly!

Posted: Tue Nov 10, 2020 9:54 pm
by abbylind
Very nice!