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Old 10-24-2019, 07:21 AM   #426 (permalink)
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Quote:
Originally Posted by DMANbluesfreak View Post
Looks like good progress! Good idea making the torsion bar crossmember removable from the start. The 205 is heavy enough and then you added another 40lbs or so haha.
I always just lifted the factory case into place, I broke down and bought a little trans jack from HF because I donít think I could get that heavy SOB into place....how did you install yours? Lol
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Old 10-24-2019, 09:37 PM   #427 (permalink)
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Carefully with a floor jack and stacked wood to level it out. And ratchet straps. It was sketchy!

I bought a trans adapter for my floor jack after the first time struggling with it.
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Old 10-25-2019, 09:05 AM   #428 (permalink)
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Quote:
Originally Posted by 06 H3 View Post
I always just lifted the factory case into place, I broke down and bought a little trans jack from HF because I donít think I could get that heavy SOB into place....how did you install yours? Lol
well worth the $80 (with coupon )
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Old 11-12-2019, 09:01 AM   #429 (permalink)
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Update with no pics:

Got all 3 shifters mounted, coilovers, limit straps, and bumps all in. Gotta repair one bump. The threaded portion for the Delrin broke off from an impact.

I am currently cutting up the floor for the 205 doubler. How much room do you need in between the floor and top of the t case? Donít want to under do it and have movement impacting shifter use or hearing the case banging against the floor.
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Old 11-12-2019, 10:07 AM   #430 (permalink)
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When I did my exhaust the first time after the SAS (from the collector back), it was around 1/4" from a heat shield bolt/stud. When I got bound up, I could feel it barely touching/vibrating against the tip of the bolt/stud. I ended up redoing the exhaust for the doubler and made sure to stay at least 1/2"-3/4" away from frame/body.

I imagine the exhaust coming off the collector moves around the same amount as a transfer case. As such, I'd leave at least 1/2", maybe 3/4" clearance just to be safe. Don't want to have to do the work twice! Since I shaved the 'foot' off my 205, it's inches away from the body - so the exhaust is still the closest thing.
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Old 11-12-2019, 11:26 AM   #431 (permalink)
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I definitely have some more trimming to do. I am probably 1/4in from the body. I am curious if I can do some light trimming on top of the NP205 in addition to the body.
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Old 11-12-2019, 12:26 PM   #432 (permalink)
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Hard to say if that highlighted area has a thin wall without opening up the case. My guess is that after the hole, the case void actually juts out into that area to keep the wall thickness from being too much (bad for casting) so you'll have to be careful with the trimming.

If you do get into the case, you'll have to plate it shut. Not a big deal, but you may need to empty the case to do so properly. Hopefully someone else can chime in if that can be clearanced.

No room to adjust the floor for more clearance?
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Old 12-16-2019, 09:12 PM   #433 (permalink)
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2 post update: I got the hummer done and running. It was with a lot of BS but it went on it's maiden voyage.

Here it is all mounted up with coilovers, air bumps, etc.



Flexing out each side to get limit straps set.



Getting the engine bay back together.



Battery was a tight fit



Trying to get organized, I love these action packers!



I built a new intake for it, I don't have pics of that right now.

Then the drama started, I went out to test drive it and had HORRENDOUS noises. It was the rear output that was making the noise. After pulling the rear output atleast 3 times I finally found that the little needle bearings that are the pilot to the rear output were not in the case! Because I had the 205 laying around so long waiting for the doubler I had it sitting for so long I must have forgot to put those 15 little needle bearings in. What a pain....So I got that back together and made the noise MUCH better but still noise was present.

I then found out I had an old style ring gear and a new style planetary. Wonderful....This is why your best to get a donor case and not mix/match these parts. So out came the entire t case again to swap in a old style planetary. I still needed a skid plate and a lot of little odds and ends so I decided to not bring the hummer to so cal for thanksgiving even though I got it driving.

Went to hammers to spot, spectate and hangout with friends but definitely missed squeaky.

Made a DIY 20lb powertank for under $250 which was sweet!



Got home and got back to working on her and finished it up. I then had a 2 way plane ticket for this past weekend because the plan was to fly in for 2 hammer trips with my buddy before his wife had their first baby. I cancelled the boise to so cal flight and kept the so cal to boise flight home. I hopped in the hummer and drove 840 miles to hammers after putting a whopping 17 miles on her at home. Crazy or stupidity, you pick.

Started to hit some bad weather on the way through Wells, NV.



Eastern Nevada is DESOLATE. Man, breaking down in NV has got to be a scary nightmare. I took the 93 all the way down to Vegas.

Stopped in Vegas to say hi to my Toyota friends.



They are down for six shooter knuckles on one and a 3 link on the other.

Hit another milestone



Got to hammers and just messed around in the desert for 30 minutes or so testing the new suspension. It is leaps and bounds BETTER! Much less body roll, the true 6in of uptravel is very welcomed in the desert and overall very happy with initial impressions.

Went to sleep to tackle Sledgehammer in the morning.

Sledge is a tough trail for me, It seems to be that one trail that just fucks me everytime. I never got the plaque, when I almost had it I broke a shaft climbing it, or winch but this time, I got it! No rock stacking just a few attempts and got it!

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Old 12-16-2019, 09:13 PM   #434 (permalink)
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2 post update....#1 is above.
After the plaque that big boulder moved under my tire and caused this



The tight left turn I should have gotten my first try, I had the right line and literally just stopped and backed up, pure stupidity on my part. This damn trail is my nemesis but I am glad I am finally up the plaque unassisted.

Then we went up "3rd canyon of sledge" it was very steep and loose but fun!



I dented my tie rod bad and my ram...damn it!

After that we went exploring and down a sand hill to bloody mary and that's when things got bad. First off the damn doubler started popping out of gear, didn't matter if it was high or low range. Then I realized my computer was going hay wire since it wouldn't recognize I was in low range.



I still had the encoder motor plugged in but it wouldnt go into low range. The encoder motor was attached to the back of the factory case. I would let it shift even though nothing is attached to it and go into low. I think the encoder motor coincidentally died after pulling my old case. So with no real way to be shifting gears I dealt with the computer going haywire and literally had to winch HUNDREDS of feet out of this sand hill. It took hours and it sucked really bad. After that we got back to camp and the weather sucked, feeling pist off and not wanting to deal with weather we left to head to my buddy's house about 90 miles away. On the way to his house the damn doubler kept popping out of low. eventually we just towed it to his place. My plan was to leave it there anyway and fly home and come back in January for another run and then KOH, then drive it back. Now I am going to pull the case the weekend I go back.

I spoke with Behemoth and he thinks it's one or two things, the snap ring for the front input let loose and is allowing it to walk in the housing or we found out I have the narrower width bearing when I need the wide double row bearing which is 4mm thicker and allowing the case to walk around. THIS IS WHY I SHOULD HAVE GOTTEN A DONOR CASE instead of mixing and matching but I got a super good free deal which was cool and appealing but now I know. The reason we don't think its the shifter is because when you hold the lever with your hand and let it run in neutral you feel like the shifter hub is walking back and forth. I was told the input snap rings stretch and since I had to swap the planetary's I had that in and out a couple times. So when I fly to my buddy's in January I will bring the right bearing and a new snap ring. I will ship him a new DIY Tie rod to weld up and a new ram so she's ready for KOH. I will wire in a switch to ground out the 4wd signal to the PCM so this computer stops freaking out. Probably easier then doing a new VSS in the back of the trans or something.

After those struggles I felt defeated and angry. I felt like my rig is too big, heavy and dumb for the hammers and I should build a late 80's square body S10 since they are little and light but after a good night sleep I am ready to keep pushing the big rig! The last time I felt that way was when I was stock and broke a tie rod and questioned should I sell the H3 and buy a jeep. Luckily both times a good night sleep will snap me out of those thoughts. they are growing pains from a shakedown run that you deal with when building a rig not many others build.

The key takeaways were driving 840 miles successfully, getting the plaque on sledge and a new suspension that feels MUCH better.
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Last edited by 06 H3; 12-16-2019 at 09:18 PM.
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Old 12-17-2019, 06:59 AM   #435 (permalink)
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Quote:
Originally Posted by 06 H3 View Post
Because I had the 205 laying around so long waiting for the doubler I had it sitting for so long I must have forgot to put those 15 little needle bearings in. What a pain....So I got that back together and made the noise MUCH better but still noise was present.
Glad you figured that out before making the trip to Cali. That could have been catastrophic.

Quote:
Originally Posted by 06 H3 View Post
I then found out I had an old style ring gear and a new style planetary. Wonderful....This is why your best to get a donor case and not mix/match these parts.
Oooof that's scary haha. Glad you figured that out, too.

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Originally Posted by 06 H3 View Post
Crazy or stupidity, you pick.
Why not both?

Quote:
Originally Posted by 06 H3 View Post
I still had the encoder motor plugged in but it wouldnt go into low range. The encoder motor was attached to the back of the factory case. I would let it shift even though nothing is attached to it and go into low. I think the encoder motor coincidentally died after pulling my old case. So with no real way to be shifting gears I dealt with the computer going haywire and literally had to winch HUNDREDS of feet out of this sand hill. It took hours and it sucked really bad. After that we got back to camp and the weather sucked, feeling pist off and not wanting to deal with weather we left to head to my buddy's house about 90 miles away. On the way to his house the damn doubler kept popping out of low. eventually we just towed it to his place. My plan was to leave it there anyway and fly home and come back in January for another run and then KOH, then drive it back. Now I am going to pull the case the weekend I go back.

I spoke with Behemoth and he thinks it's one or two things, the snap ring for the front input let loose and is allowing it to walk in the housing or we found out I have the narrower width bearing when I need the wide double row bearing which is 4mm thicker and allowing the case to walk around. THIS IS WHY I SHOULD HAVE GOTTEN A DONOR CASE instead of mixing and matching but I got a super good free deal which was cool and appealing but now I know. The reason we don't think its the shifter is because when you hold the lever with your hand and let it run in neutral you feel like the shifter hub is walking back and forth. I was told the input snap rings stretch and since I had to swap the planetary's I had that in and out a couple times. So when I fly to my buddy's in January I will bring the right bearing and a new snap ring. I will ship him a new DIY Tie rod to weld up and a new ram so she's ready for KOH.
In the interest of having ALL the possible parts you need, perhaps it'd be wise to ship him an entire NP241 front case half? That way you know it's all matched and your risk minimized. Just a thought.

Quote:
Originally Posted by 06 H3 View Post
I will wire in a switch to ground out the 4wd signal to the PCM so this computer stops freaking out. Probably easier then doing a new VSS in the back of the trans or something.
Where is your current VSS? In the NP205 output?

Quote:
Originally Posted by 06 H3 View Post
After those struggles I felt defeated and angry. I felt like my rig is too big, heavy and dumb for the hammers and I should build a late 80's square body S10 since they are little and light but after a good night sleep I am ready to keep pushing the big rig! The last time I felt that way was when I was stock and broke a tie rod and questioned should I sell the H3 and buy a jeep. Luckily both times a good night sleep will snap me out of those thoughts. they are growing pains from a shakedown run that you deal with when building a rig not many others build.

The key takeaways were driving 840 miles successfully, getting the plaque on sledge and a new suspension that feels MUCH better.
Yeah it's always tough when a fresh build has issues, but I think if you keep after the gremlins, you'll have a super stout drivetrain again and not have to worry. The silver lining is that the suspension seemed to work flawlessly and you should be proud about that.
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4L80e, EcoBox/205 Doubler, 40" Mickey's, Rock Sliders, Hidden Winch, Hydro Assist

Last edited by DMANbluesfreak; 12-17-2019 at 07:00 AM.
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Old 12-17-2019, 08:26 AM   #436 (permalink)
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Quote:
Originally Posted by DMANbluesfreak View Post
Glad you figured that out before making the trip to Cali. That could have been catastrophic.

I was told most people don't even realize those little 15 needles in there since they are covered by a washer

Oooof that's scary haha. Glad you figured that out, too.

That was another issue figured out

Why not both?

LOL I would agree both!

In the interest of having ALL the possible parts you need, perhaps it'd be wise to ship him an entire NP241 front case half? That way you know it's all matched and your risk minimized. Just a thought.

That isn't a bad idea.

Where is your current VSS? In the NP205 output?

Yep its in the rear output of the 205

Yeah it's always tough when a fresh build has issues, but I think if you keep after the gremlins, you'll have a super stout drivetrain again and not have to worry. The silver lining is that the suspension seemed to work flawlessly and you should be proud about that.
I am ready to go back to hammers and kick ass lol
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Old 01-17-2020, 05:50 PM   #437 (permalink)
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Awesome build!
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