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Willys M38 A1 - "Klinger"

This is a discussion on Willys M38 A1 - "Klinger" within the Domestics and Foreigns forums, part of the Vehicle Specific category; Renovations at the office are complete but still have not been able to get started on the transmission overhaul. My ...

  1. #61
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    Black & Blue
    '02 WS.6 / '07 Suburban

    Renovations at the office are complete but still have not been able to get started on the transmission overhaul. My brother-in-law with the body shop took a look at Klinger for the first time over the holidays. He thought that the paint applied over top of the markings might come off. Over the weekend, I soaked a rag in lacquer thinner and sure enough, the paint wiped right off and did no harm to the markings or the color coat. Somehow I missed the tire pressure markings and still have to do those but a total improvement in how Klinger looks.

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    '02 WS.6 / '07 Suburban

    Transmission is rebuilt - all new small parts, bearings, countershaft, 2nd gear, synchros, 2-3 shift assembly, synchronizer plates, and throwout bearing assembly. I ended up pulling the bell housing off the engine. Not a whole lot of fun, but glad that I did. The clutch has been replaced and looks to be brand new. Unfortunately, they utilized a mix of bolts to install it, including a couple of hardware store Grade 2 bolts. Replacing everything with Grade 8 bolts this morning and then will attempt to install the transmission and bell housing as a unit. Transfer case is in the parts washers coated with over cleaner. I did the same for the transmission and 65 years of grime melted away and cut scrub time to a matter of minutes.

  3. #63
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    Fail. Cleaned up the transfer case and flushed out the innards a few times last night. My attempt to install it solo failed miserably. The transmission output shaft bearing is sandwiched between the transmission and the transfer case and I just could not get it to slide together. In taking it back off, I accidentally separated the transmission output shaft from the input shaft and a few of the needle bearings fell out. I called it quits around 9:00 last night and will give it another shot tomorrow.

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    2016 Camaro SS - Summit
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    It's never fun when things like that don't go as planned, and REALLY not fun when you create more work for yourself in the process of failing. Been there a few times, with the T/A, the old SS and most recently my brother's 67 C10. BUT, it's most satisfying when it all finally comes together. You'll get 'er there soon enough. Good luck on the second attempt

    2016 Summit White 1SS - The DD - Mishimoto catch can, Solo axleback & secondary cat delete, LED sidemarkers & reverse lights, head/taillight blackout, RCC custom badges
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  5. #65
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    Here are some of the pics detailing the rebuild process.












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    '02 WS.6 / '07 Suburban

    As you can see, it was about as dirty and nasty as these things come. The cleaning process started with scraping the transmission case and transfer case with a paint stick and flat blade screwdriver to remove the layers of grime. I then dropped them each into the parts washer and coated them liberally with oven cleaner. I kept them "wet" by applying additional coats of oven cleaner and let them each soak for several hours. I then fired up the parts washer and scrubbed them down with a brush. Although I ended up plugging two filters, despite my pre-filter in the drain, the cleaning process went much quicker than expected.

    The transfer case was especially nasty:






  7. #67
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    Black & Blue
    '02 WS.6 / '07 Suburban

    Well, we are back together and running again. Unfortunately, there is an issue on the 3-2 shift. The transmission works perfectly on the R-1, 1-2 and 2-3, but I can not get it to shift 3-2. It will come out of third into neutral but not engage second. Even double clutching (which I almost always had to do previously) does nothing. On the bright side, it no longer jumps out of second on downhill runs.

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    Fixed. After taking the shift assembly off, I could see a small hot spot on the synchronizer assembly and third gear synchro. Looks like things had to "clearance themselves" a bit as I have some brass filings in the fluid now. After reassembly, and a few failed attempts, I was able to make the 3-2 shift double clutching it.

    We loaded Klinger up yesterday and went to a family gathering and some trail driving. From there we trailered north into New York for some more trail running. Other than an occasional stall and hard re-start, Klinger did incredibly well. Today, we went on our longest ride yet down to the lake and Klinger performed flawlessly.

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    Black & Blue
    '02 WS.6 / '07 Suburban

    Great thing about a Jeep? I don't need the big trailer to haul it!



    This is from our ride on Sunday afternoon down to the lake.


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    God I feel the roads from Honduras again just looking at those pics.....

  11. #71
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    '02 WS.6 / '07 Suburban

    Looks like northern Pennsylvania to me.

    Ordered up another round of parts for Klinger -- differential cover gaskets, fuel pump, rear seat belts and a gas cap gasket. Worked on installing the front seat belts last night and have the driver side completed. Still lots to do -- replacing engine mounts, installing the engine ground strap that is missing, drilling the plug out of the block to plumb the oil feed line to the filter canister, need to get the speedo and fuel gauge working, install turn signals, add a brake/marker light assembly on the back right, get the horn working, install rear seat belts, mount the license plate, may mess with the vacuum wipers at some point, adjust the e-brake, and likely rebuild the carb and bend up a pump to carb fuel line. That's the short list!

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    2016 Camaro SS - Summit
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    That sounds like a day or two's worth of work...

  13. #73
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    '02 WS.6 / '07 Suburban

    Good thing I have nothing else to do! I knew this one would be an ongoing project, but it pretty much ends up being the same treatment we give all of our vehicles once they join the family. A very thorough going over to ensure that they are both safe and reliable.

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