Anyone Ever Overhaul a PIlothouse Tranny?

[grey beard]

My gear box must come out - for two reasons: It leaks from several spots - mostly where it joins the bell housing, and the second gear synchronizer is gone.

My question to those of you who have had them apart is this - what can possibly leak at the front of the case, other than the counter shaft hole? I have a gasket in front of this but it still leaks. Mebby the case is worn?

I'm open to suggestions. Prolly won't get into this till the summer show season is over.

Thanks

[MBF]

GB-is there an oil slinger on the input shaft? Could the input shaft cover gasket be leaking? How about those holes in the top for the shift rods (leaking between the front of the tanny and b/h? Mine piddles too but out of the rear-needs a new seal which I finally got the p/n for. I have a 4 speed in my garage that I was going to put into my truck, but it doesn't fit the bellhousing I bought SO she's staying a 3 spd. I'll look at that and see if there are any other places she could leak from. I plan on going through the 3 spd this winter cuz she's going to Macungie next year under her own power. I refuse to let your truck have the honor of being the only PH on the show field! They'll look good sitting next to each other! Mike

[grey beard]

Hey Mike,

Just took a quick gander at the parts book. As you suspected, there are two gaskets on the input shaft bearing retainer and two on the output bearing retainer plus the seal you mentioned at the output shaft. My book shows it as part number 600 402.

Like you, I also plan on pulling my gear box this winter. I have a 2nd gear synchro that doesn't. Period. Gotta' double clutch to keep from grinding, plus the floor puddles. Soooo, out she will come after show season.

Please know that I will reserve a spot right next to mine for you at Macungie, if I get there first, and shall expect your Pilothouse presence, for sure. Sure wish I knew someone who was a director.

Looking forward to that.

[MBF]

One of my ideas for next years show is valet parking for PH's! If that doesn't fly we can always leave them in the parking lot and wait for someone old enough that knows what a foot starter and hand choke is to come along and move them to the show field! Took her to a cruise in Monday night-heading to another one this Friday. I've put almost 1000 miles on her this year so far and haven't been anyplace! Mike

[grey beard]

This goes in the category of being sorta' stupid, in that I should be embarrased to admit it, but here goes. Whenever I jack up my truck to work underneath, I generally jack from the front axle. That's where the jack is, that's what I'm used to doing, and the jack stands are close by, etc.

Welllllll, would you believe that when a Pilothouse is jacked up from the front end and is no longer level, if you add trans oil in that position, and then level it off, the lube level is quite a bit over-full? It is . . . . . .

Had my Pilothouse up on my brother's lift last week. First time I've ever had it on a lift and could walk around underneath. In the level position, I had the presence of mind to check the trans lub, on account of all it's been leaking lately, and I didn't want to run the poor thing dry and add insult to injury.

Imagine my surprise when I discovered the tranny to be not very low, but quite a bit OVERFULL! Drained out about a cup of extra lube and guess what? Now it doesn't leak a drop.

Looking at things in hindsight, it is now apparant that when the unit is overfull, oil comes out past the input shaft bearing up front, and drains down past the bell housing. Now that the oil is at the proper level, the unit is dry on the underside and there are no spots where it is parked for several days.

Just passing this on for others' benefit, because I'm sure that I am not the only hobbyist on this forum who does not work with a lift. This information did not fix my bad 2nd. gear synchro, but it sure did fix my leak.

[MBF]

GB-that's understandable. I can roll under my 1 ton on a creeper with her sitting on level ground and check fluids, change oil, do lube jobs etc. You can't do the same with a 1/2 ton-no ground clearance. Glad it worked out well for you. Sometimes its the simple things that get ya-been there and done that! Its expecially embarrassing when you're wife points it out to you-at least you saw this on your own. Mike

[Young Ed]

Dave does your 2nd gear stay in once shifted? I have to double clutch mine too but it does stay in gear once you get it there. I've just been living with it.

[grey beard]

Young Ed,

Now that my transmission leak seems to have taken a rest cure, I'll likely decide to live with this one, too. It grinds on a 3/2 downshift unless I double clutch. Not too noticeable on the 1/2 upshift, especially if I take my time, but downshifting takes some holding of the mouth in just the right attitude insofar as matching engine and road speed on the double-clutch downshift interval. Other'n that and a few whines and grinds, it's a truck tranny and does what it was made to do. There are no issues involving popping out of gear at all, fortunately.

The other thing I have noticed is that finding parts for these things is a tad problematic. Thought I might find a spare gearbox and build it up this winter in my spare time, but haven't even been able to find a synchro kit or individual blocker rings. Maybe not finding parts to rebuild it is a pretty good reason for living with the problem.

[Paul Beard]

Dave i do not know if the same company buit both the three and four speed tranny's used in the PH trucks but my four speed is am New Process. The same tranny used in ford trucks with stick shift ( at least in the late seventies and early eightys).

[Young Ed]

Stange mine seems to be ok on downshifts but grinds on upshifts once the oil gets warm. I have a few spare gear boxes but so far I haven't bothered to try any of them out.

[grey beard]

Welllll,

Looks like I spoke too soon. Moved the truck and found another trans oil puddle, so my leak is intermittent - sometimes it behaves and sometimes it leaks. Mebby it's the phases of the moon or what? Who knows .. .

Anyhoo, this means it's gonna come out this winter if I can find any parts for it. Still looking. I'd like to put new bearings and a rear seal in while I have it apart to do the synchronizer. Sure hate a leaker . . . . . dratt!