W150 pulled the Transmission and transfer case

 Pulled the tranny and T case as one.

 Now to find a NV4500 or a NV5600 Transmission to replace the NP435.

 I counted all the spines just to be certain, 23 on the input and outputs shafts.

 Rebuild time for the T case, the internal movements feel a bit off.

Rust repair of the air handler on the W150

This is the patch for the driver’s side. It was cut, formed and screwed into place in an effort to minimize any gaps.

 Quarter inch holes were drilled in between the screws and then plug welded to join the layers. The screws were removed and the holes welded closed.

 Passenger side patch.

Some of the duct was rusted thin and made for some burn through, the repair of witch made for a lot of ugly welds.

Playing catch up, during the winter Breaks, Bearings and gas tank on the W200

W200 Club cab

 My truck the W200 was up on the lift from February to April.

While it was up it got all new breaks (soft and hard lines, Calibers, Pads, shoes). 

 The front passenger side wheel bearing and inner axial were trashed as the last guy who had it apart did not assemble the bearing in the right order. The front axial is a Dana 44-HD just like on the M880. I got a used font right axial off of eBay, new bearings from the local parts store and was a victim of highway robbery at the local dodge dealer ship for an Axial Nut..

The new soft lines did not bolt up correctly, I fabricated an adapter. These lines are far easier to find and less expensive than NOS.

 Replaced the upper and lower ball joints.

 The W200 has an after market trailer break controller. I might keep if it cleans up nice. I don’t  like the idea of putting a T on the break line(as see in the photo) and running that line trough the fire wall and into the controller on the dash.

 I went through the differentials changed the gear oil and and by April thought I could at least drive it around the yard, my mistake.

   1. The power steering rubber line was leaking like a sieve.

   2. The break booster diaphragm had a large vacuum leak. So I thought way not make a clean sweep and replace both the Master cylinder and the Break Booster. The way all new breaks.   

The Gas tank fuel level sending unit for these tanks are crazy expensive. Since I am doing two of these 78s I bought one sending unit and I am using it as a guild to remake a generic unit to the same spec. 

Leafs + water = this all ways rusts out

Continuing cab rust repair and clean up.

 The bottom of the air handler rust out predicable as derby and water collects in the air duct. Seen here is the cut away passenger side view.  The thinned rusty metal is removed.

 A patched fabricated out of new sheet steel with a hammer and sandbag. The patch is ¾ of an inch bigger than the hole on the two overlapping sides. I cut a drain into the bottom of the patch to help remove any future derby. I will let you know is it works in another 35 years.

 

 To hold the patches in place I predrilled some 1/8 inch holes trough the over lapping parts and screwed them tight together.

 

 I then drilled some ¼ inch holes in the outer layer between the screws and plug welded in the patch.  The screws were then removed and the 1/8^th inch screw holes welded shut.

The driver side. 

 This sides patch placed on the out side to show overlap and predrilled screw holes.

 Patch in place.

 Screwed.

welded.

Ugly I know but that's what the fender will hide.