Here's the latest project that's been in the shop, still is, but making progress forward. This is a long one, lots of reading...
Ford 3500 KD forklift. Neighbors rig. He called as said he lost a couple gears. Went over and found that it broke a shift fork. Could get the broken pieces removed, but no way to install a new one. Shift rail didn't move far enough.
In Fords infinite wisdom, you have to backspin the tractor to remove the shift rails, to remove the shift forks.
Got counterweight dropped off, then rolled the diff housing away from the engine and speed trans. That's when things took a turn for the worse.......
First, found a broken tooth on a gear in the speed trans. Have to remove trans from engine to pull bearing and snap rings off front of topshaft, to disassemble top shaft.
Found clutch, that wasn't terribly old, had a finger/lever that was missing a piece and was cracked.
Then found metal filled goo in the bottom of diff housing, along with lots of chucks of metal. 3 bearing rollers came out when I dropped the oil.
Pinion had been flopping around forward and back. Like 0.150" endplay. Saw the ring gear had a chipped tooth. Pulled pinion out and found the flat roller bearing had lost all its rollers, inner and outer races were broken. Shaft was missing thrust washers behind the nut.
Looked in the fill hole, found differential carrier was missing 5 out of 8 bolts... so then I pulled axles off and dropped the diff out.
All 8 bolts were sheared off, just 3 hadn't completely fallen out yet. Spider has been working back and forth long enough it moves about 1/8in. Toast.
My guess is the washers behind nut on pinion broke, which then let the pinion move around. That then tore out the flat roller support bearing. I think then the rollers wedged between pinion shaft and diff carrier. And wedged it tight enough it tried to push the 2 halves apart. Axle housings keeping it together.
It's a giant mess. Nothing was wrong except for a broken shift fork when I started.
A 3500 is its own animal, yes its basically a 3000 tractor. Lots of differences in the back. Luckily was able to find everything I needed at All State Ag Parts in Ft Atkinson IA, and resonable too.
Got speed trans back on Thursday night. Hopefully go back together with diff housing tomorrow.