What's new
CK5
Register an account today to become a member! Once signed in, you'll be able to participate on this site by adding your own topics and posts, as well as connect with other members.

K10: Built HP60/241-205 Doubler/tons of tube

Overview Gallery Discussion
The main reason I swapped mine to disc, was price....

Drum service is almost 2x what a disc swap was.
Disc service is faaaar easier/faster.

:D
 
Well CRAP. I put the doubler back together tonight and I'm having issues. Everything in the 205 works, independent control of both front and rear outputs. High/Neutral/Low and you can't put one in high and one in low so that's all cool.

But on the 241 3 detent spots are high range and one is low but in low if you bump it it'll pop out of gear and I don't have a neutral anymore. The fork only goes one way so it can't really be backwards like I was initially thinking. Can you put a 241 together with the slotted plate and the nub that raises and lowers the shift fork off a little? That seems to be what's going on, it's like it slips past the neutral spot and runs out of throw to get seated really well into 4 low.

IMAG0450.jpg


I'm going to tear it back apart tomorrow night and see if I can figure out what's going on. Any ideas? I
 
Sadly in this case not much. I really need to be making better progress on this stuff to be ready to roll for this summer. The big thing hanging over my head right now is getting this back together and working then figuring out how I'm going to do the cable shifters and build all the related brackets for that.

I'll just have to yank it apart tomorrow night after work and see what's going on. If I only lost neutral I wouldn't care because I have neutral in the trans and in the 205 but not locking really tight into 4 low has me thinking something just isn't right. I bet once I fix one issue the other will resolve itself too.
 
Maybe you need a new shift fork? I wonder if it has to do with the new input shaft setup, but I don't see how that would matter. Maybe when you put the case halves back together on the 241, something didn't go together quite right. Whenever I have a problem, I automatically suspect the things I've had apart, no matter how simple it my have been.
 
andyblack said:
Maybe you need a new shift fork? I wonder if it has to do with the new input shaft setup, but I don't see how that would matter. Maybe when you put the case halves back together on the 241, something didn't go together quite right. Whenever I have a problem, I automatically suspect the things I've had apart, no matter how simple it my have been.
Click to expand...
thats the first thing that jumps to my mind as well...
but when ever i played with it, it seemed to hold each shift fine?
i can try my 241 with your shaft in it tonight and see if anything seems off? but idk.
 
I'm just thinking that either the shift fork is worn more than what we could see in the pic, or it's just not quite in the place where it needs to be. When he split the case to install the new input, he probably only had to take out a few things like the planetary assembly and shift fork and stuff like that, so hopefully he can just take it apart and put it back together again and it will work. :whistle: That's happened to me before. Hoefully it's just sitting on his workbench and not installed in the truck yet. I'm sure that thing is HEAVY.
 
Yeah don't worry about it Steve I'm sure its just something that didn't sync back together right. I'm free tonight after work so I'll pull it apart and see what's up. I shifted it all before I put it together and it was fine so something happened when it went back together.
 
Well I pulled it apart tonight and as I was loosening everything I started trying gears and it clicked into 4 low nice and tight... I clicked it back one and it had neutral back.
So I continued to pull it apart and upon closer inspection all I can find that isn't 100% gravy is the end of the rod the shift fork rides on is drilled and tapped what appears to be off-center just a hair and I'm thinking when I put the bolt through the adapter plate and sucked it tight it was binding.

Again though, that's all I can think of, maybe it doesn't make a lick of difference as we're talking something that's off-center less than 1/16".

So I cleaned up all the RTV and put it back together but made sure I shifted it through the gears as I was tightening up that little bolt on the end of the shift fork shaft. Everything is working like normal now so it's ready to go.

Now I have to figure out the shifters. Not sure what I'm going to do yet. I've been getting ideas searching through pictures but obviously nothing I can really copy since there aren't too many 241/205's out there and the ones that are done aren't done like this one is.
 
I had a samurai case that I had regeared once, could not get it to shift correctly at all, weirdest thing would not go into 4wd low range.

Well I was gone for a couple days, guy who owned it came by filled it up ( unaware of the problem) and took off.

It shifted fine after filled with fluid :confused::confused:, been working now for a couple of years.

Nice progress Avery going to be paying attention to your cable shifter as I hope to go to a 241 doubler this fall.
 
Looks great. I am super happy with my 241/205. Am interested to see how your cable shifters come out too. I built this swing set deal and was kind of a pain in the ass to do, but works. Might have been easier to do the cables.
When I was researching the 241/205 doublers one guy had a problem with the threads stripping out of the aluminum on the 241. So when mine went back together I put some longer bolts through and put jam nuts on the back of all the bolts between the plate and 241. Just a thought.
 
ssyork said:
So when mine went back together I put some longer bolts through and put jam nuts on the back of all the bolts between the plate and 241. Just a thought.
Click to expand...

Good idea, might have to do that before it goes in.



Sold my core TH400 and rebuild kit for $200 then sold the front 10b that came out of the truck for $220 to his friend then gave the first guy his money back and bought these 39.5" TSL's he wasn't going to use for $200. Probably one of the better deals on something I've ever had.

Screaming for some TWF H1's :D
IMAG0469.jpg

IMAG0466.jpg

IMAG0465.jpg


So I guess that solves that, the k10 will be on 40's. :)
 
The K10 and other fun truck stuff has to take a little break. I'm making some mounts and cages for a pair of new insanely expensive projectors and long throw lenses that we're putting up in the auditorium at church. It's 1/4" base plates and expanded metal cages that I'm bending up. I'm making another one in the morning then making tabs to bolt the cages to the base plates. There's some other little things they need too but that's the basic idea.

IMAG0470.jpg

IMAG0471.jpg
 
Dang! 1/4" plates to mount lights? Must be some seriously heavy stage lights?
 
:haha: I read projectors in your original post about it, and was thinking you were talking about projector headlights. Then I realized you were talking about equipment for the church, but I never did get the image of headlights out of my head - thus my mistake. :D
 
Dumb question here, but won't the cage show up on the screen because the projectors are behind the metal grate? Or will it show up? It may look like the pastor is in a cage on the screen or something. :haha:

Or will you cut some holes in the cage?
 
You must log in or register to reply here.

Latest Posts

Top Bottom