Hodakaguy M38 Misc Thread

HodakaguyTom · Posted: Tue Jun 18, 2024 5:47 pm Post subject:

Added a replica M1 Carbine to the gun rack, looks great. Now people will know what it's for, lots of questions asking what the gun rack is.

Hodakaguy

HodakaguyTom · Posted: Wed Nov 27, 2024 7:15 pm Post subject:

Took the FJ40 & the M38 to our local car show, Cool Desert Nights. Did the cruise on Thursday night and we had four 40's in the cruise...way cool!

The show was great and we spoke with a ton of amazing people. Sooo much fun!

We arrived early to get a nice spot In the shade...1st and second in line Smile

Had another 40 as company. Way cool.

Hodakaguy

HodakaguyTom · Posted: Wed Nov 27, 2024 7:15 pm Post subject:

Winter is here...time for some M38 maint! Although the Jeep has been running great it has a couple issues that need to be dealt with. First and foremost is oil leaks, the jeep is hemorrhaging oil from the transmission and transfer case leaving a lake of oil on the garage floor. Oil needs to be topped off often when driving the Jeep and it's making a huge mess under the Jeep and everywhere it parks. The trans also suffers from the common T90 popping out of second gear syndrome on Deceleration.

Time to pull the transfer case and transmission and get these issues fixed so it's ready for fun next summer.

Oil filling the drip pan and soaking up towels....

Getting a bit more working room under the Jeep. I used my spare set of Honda Civic wheels to jack up the jeep. The wheels work great as they are dished in the middle and lock the tires in place nicely.

Pulling the skid plate

Draining oil on the transfer case and transmission.

Labeling parts for easy identification.

Rear drive line removed.

Covers removed and top of trans removed.

Will take a better look at internal parts soon.

All for today. More to come.

Hodakaguy

HodakaguyTom · Posted: Wed Nov 27, 2024 7:17 pm Post subject:

Made a bit more progress today.

Pulling the transfer case shift lever pin and removing the shift levers. The M38 has a nice removable cover that makes this task easy.

Draining the fuel tank for removal. The fuel tank needs to be completely cleaned out so I'll be removing the tank and cleaning it thoroughly before re-assembly. I keep a siphon setup on hand that works great, it's a air nozzle stuck into the end of a piece of fuel line, the air creates a vacuum that pulls the fuel through the hose nicely and starts the siphon. The tank does have a drain plug on the bottom of the tank but it's stuck pretty firm so I used the hose.

Removing the vent line, clutch clevis and engine stay.

Using a Harbor Freight transmission jack to lower the transmission/transfer case. I kept the cross member attached and used two ratchet straps to secure the units to the jack. It worked like a charm.

Separating the transmission from the transfer case. The previous owner used silicone on everything, making disassembly a bear. I ended up having to use a thin paint scraper and heat to separate the trans/transfer case.

Removing the nut inside the transfer case in preparation to separate the two. Once the cotter pin was removed the nut was already loose, easily spinning off by hand.

Placed a piece of wire on the cluster to keep everything forward during disassembly.

Cross member removed.

Dealing with more silicone.

The rear plate and bearing stayed on the transfer case during separation due to large amounts of silicone used.

Disassembling.

No metal bits in the bottom of the case.

Lots-O-Parts

Lots of wear on the gear teeth.

I'll be completing a more thorough inspection soon so I can get replacement parts on order, along with completing the tear down of the transfer case.

More to come.....

Hodakaguy

4x4M38 · Posted: Thu Nov 28, 2024 9:39 am Post subject:

Somebody really worked over the trans.

What kind of shape is the clutch and throw out bearing? Might change the bearing anyway since you have access.

Since everything is out check your pedal shaft for wear also. The pedals wear on the inside where they ride on the shaft and they get play in them. They should move straight forward and back with no slip side to side.

I’m guessing all the silicone was to keep it from leaking, lol.
_________________
Brian
1950 M38
MC11481
http://www.willysmjeeps.com/v2/modules.php?set_albumName=album372&op=modload&name=gallery&file=index&include=view_album.php

HodakaguyTom · Posted: Fri Nov 29, 2024 8:22 am Post subject:

HodakaguyTom · Posted: Fri Nov 29, 2024 8:22 am Post subject:

Time to take apart the shift tower.

Driving out the pins on the shift rails.

Drifting out the shift rails.

Plugs removed.

Shift rails have some pitting on them.

The high intermediate shift fork has some slight wear, enough to catch a finger nail on.

One of the shift rail indent springs was broken upon removal.

Starting to disassemble the transfer case. Pulling the E-brake drum

Rear drive flange has some wear/pitting at the seal interface.

A bit of oil on the E-brake assy....wonder why it didn't hold very well lol.

Checking as found end play.

Shim Pack

Speedo drive gear looks to be in good cond.

Lots-o-parts

Front output flange has some wear/pitting at the seal interface as well.

Removing the oil pan

Intermediate shaft gear. Slight Pitting

More gears.

More to come.....

Hodakaguy

4x4M38 · Posted: Fri Nov 29, 2024 8:52 am Post subject:

Did you find any safety wires when you were disassembling?

I sourced all US or Japan bearings when I rebuilt mine. It took some doing.
Also had to shop several of the MV suppliers to get all my rebuild parts. No one had them all, and there were a couple with slight differences in pricing.

All good reliable parts.
_________________
Brian
1950 M38
MC11481
http://www.willysmjeeps.com/v2/modules.php?set_albumName=album372&op=modload&name=gallery&file=index&include=view_album.php

HodakaguyTom · Posted: Sat Nov 30, 2024 7:26 am Post subject:

HodakaguyTom · Posted: Sun Dec 01, 2024 7:37 pm Post subject:

More disassembly and inspection on the transfer case.

Main shaft gear shows some wear on the inner splines, as well as some isolated pitting on the main teeth.

Shift fork bolts wired in place

At first glance the output shaft gear and sliding gear look in pretty decent shape. A close inspection of the teeth show pitting deep enough to go through the hardened metal.

Minor pitting on both output yokes.

Pulling the seals out of the front output shaft housing.

Shift Rails show pitting where the seal rides. These will be replaced.

Shift forks

Checking clearance between the case and the shift rails. There is some slop here, although it shouldn't affect anything in operation. No allowable clearance is given for this clearance in the Army repair manual.

Lot's of parts on order. Now to get everything cleaned up and prepped for re-assembly.

More to come.

Hodakaguy


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