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Discussion Starter #21 (Edited)
FS-8406 Score

:thumbsup:thumbsup:thumbsup

Sorry ya all missed out on the great Ebay deal on an FO-8406---$152.50.

It was improperly listed and read "EATON F-8406N-AW3 TRANSMISSION GEAR REDUCER"

Looks like things just got really cheap on the conversion. Freight is going to be $178.00 so my total cost so far is

Flywheel Cover $75.00
FS-8406 Trans $330.50
FSO OD Gears $150.00 estimated
Flywheel & Clutch $550.00 estimated
#2 Fuller Bellhousing$200.00 estimated
MT 28 starter $000.00 have one
Driveline Rework $75.00 Balance only
$1,380.50 Estimated Cost

If you need to source some tranny's go to HeavyTruckParts.Net - Search for Parts

Arrow Truck Parts in CA has all of the parts less trans for $1,000 and it's off a truck with only 500 miles.

Guess how I feel??? :hyper::hyper::hyper::hyper:
 

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Discussion Starter #22
REMan,

I passed up on the ESO's because of the input from several tranny shops--their advice was "stay away if you can". I agree with you on looking at options. There may be other possible direct to OD conversions out there.

The FSO-8406A makes the conversion bullet proof. Most go 500,000 before they need work and if you change out the pilot, input shaft and bearing, you could go 1,000,000.

If I get only 500,000 from my used Fuller, my cost will be $0.000661 per mile. With my NV5600 so far, the cost has been $0.060714286 which includes the dead trans in the snow, and if I replaced it again, the cost would be $0.091964286.
 

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Discussion Starter #23
More Transmission Options

Hi All.

From the number of views on this thread, there seems to be a lot of interest on the use of a Fuller transmission with our Cummins 5.9.

Here's some more good news----the early 90's FS-6306A can also be converted into and FSO with the same parts as noted earlier. Go to http://www.euroricambi.com/cataloghi/35/PAGES/414-423.pdf for parts and illustration. These are very plentiful and cheap. Gears very seldom get torn up. Usually requires input shaft, trans beaings and input flywheel pilot, then you're good to go for another 250,000 miles. Any sucess stores out there that a NV5600 made it that far? Ok, maybe 1 but not 2 !!!!!

I am almost done with my prep for my DT466 to install in a 3 yd wheel loader and I can get back to the conversion. I am now waiting for my $152.50 FS-8406A from Ebay to arrive. Should here by March 7 or 8th. It has a 2" input shaft and will have to be replaced in order to use a "push" type clutch. Is it fair to get such a deal and have to pay $178.00 in freight to get it home??

Anyone out there contemplating this conversion???????
 

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Discussion Starter #24

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Discussion Starter #25 (Edited)
Good News

My Ebay transmission arrived late today. Didn't know what to expect since it was bought sight unseen and it was mis-identified in the description.

Here's what I got---a brand new never used FSO-8406AWS built on 4-24-06 totally complete. Probably another lifetime before this happens again. What a buy on Ebay for $152.50.

Now I can work on the 14" flywheel, #2 Fuller flywheel cover, and clutch.

Then it's on to the Ford Excursion adapter for the transfer case. Just been too busy at work to make the calls when they're open.
 

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My Ebay transmission arrived late today. Didn't know what to expect since it was bought sight unseen and it was mis-identified in the description.

Here's what I got---a brand new never used FSO-8406AWS built on 4-24-06 totally complete. Probably another lifetime before this happens again. What a buy on Ebay for $152.50.

Now I can work on the 14" flywheel, #2 Fuller flywheel cover, and clutch.

Then it's on to the Ford Excursion adapter for the transfer case. Just been too busy at work to make the calls when they're open.
Post a pic or two!
 

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Discussion Starter #27 (Edited)
It's not an FSO-8406A Fuller 6 Speed

I tried to post photos to the gallery and was unable to do so. I will set-up a link to my web site and post them on Monday.

I took the time today to really examine my prize tranny and discovered it in not what I thought it was--an FSO-8406A. It is an FO-8406A-AW3--the latest and greatest by Fuller. This thing (a manual transmission) has the capability of being shifted by computer just like an automatic, except that it has a clutch and it's needed to stop and get the truck rolling. Go to Medium-duty market gets Eaton AutoShift to see how this works.

I won't be able to use it in the auto-mode because I don't have all the computer goodies. I'll just place a shift lever in it, plug all the computer sensor holes and use it like an FSO. See http://www.roadranger.com/ecm/groups/public/@pub/@roadranger/documents/content/rr_fo-8406a-asx.pdf for the FO set-up.

Have to see if I'll be able to use the input shaft that came with it. Should have the rest of the parts next week.

This tranny has to be worth $9,000 or so--any thoughts?? It measures only 1/2" longer the the NV5600.
 

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Sounds like you are making good progress on this swap, make sure to post up some pictures soon though.

I always wanted to put a Fuller 8LL in a dodge pick-up....would be much more fun in the Dodge than it is in my dump truck.
 

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Discussion Starter #29
Photos in the Gallery

:thumbsup Ok--slept since yesterday and finally figured out how cut down on the file size for the photos so I could up load--now posted in the Gallery:peelout

Pics are of the
NV5600--injured
New Fuller 2 pics
#2 SAE Flywheel Cover
 

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Discussion Starter #30
Parts Sources

Found an excellent source for Fuller Trans parts including new units at a very reasonable price...see Anderson Brother's Inc. Trucks, Parts, and Equipment

If you are working on adapting any type of transfer case to various transmissions, go to the Neapco site at Neapco - Aftermarket Catalogs

No parts arrived this week. Working on the adapter to the transfer case. Local Ford dealer was no help--no catalogs yet. Researching other options such as a couping shaft 2" X F-38 to the 241 T-case and simply fabricating a cage from the rear bearing cover on the Fuller with a mounting flange for the T-case. All would be a bolt-on adapter.
 

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That's right in my neighborhood. Well, almost. I was in there a couple years ago when I noticed the old Maxim ladder truck (T-22) I drove for Portland Fire parked on their lot. I could have owned it for 5,000 bucks. Trouble is, it would have taken up half my driveway. :thud: They have a lot of stuff there.
 

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Discussion Starter #32
Throw Out Bearing

I've been looking into solving the clutch release (throw out bearing) issue and stumbled across a hydraulic release bearing application that is used in some domestics, resto-rods, dragesters and sprints.

I need a source for a bolt-on or slip-on for a 1-3/4" shaft. See http://www.mrracingequipment.com/M&R Racing Equipment-Catalog Files/PG113.pdf or http://www.speedwaymotors.com/p/4378,41_Quarter-Master-Floating-Hydraulic-Throwout-Bearing.html


The other option is to retain the original "push" clutch fork assy on the NV5600 and adapt the pivot ball into the #2 Fuller bellhousing and properly set and align the slave clutch cylinder. This will take a little fabrication usless I can locate a bolt-on or work with Fuller Tech support to find me the parts to work with the Dodge hardware.
 

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I'll be following this closely. I have had way too many failures with my 6 speed. I haven't had any money to do anything about it for awhile, and really don't want to blow another 3k on a junk transmission. Did you rule out a 7 speed? I like the one in my IH 4900.


Dave
 

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Discussion Starter #34 (Edited)
7 Speed Option

:hyper::hyper: Dave,

I'm on the same boat as you, just looking for a way out. I didn't want to toss another $3k out the window. If you can make a 7 speed work, go for it---adapt, adapt and adapt.

So far I'm confident I'm on the right track with what I have chosen to do. There are many others who will be facing the fix or toss choice with their NV5600. Seems that the going rate is $3.5K for a NV5600----- what will they do when it hits $5K?????

No, I didn't rule out the 7 speed, just wanted to be sure I could get the gear ratios correct. If you have something less than a 4:10 as I do, a direct drive will work. There are numerous 12V compressors that could work with an air shift. I was just trying to avoid more work---not lazy, just practical.

If you look at the posts, all those people with grinds, growls and binding are just one shift away from NV5600 failure. When my symptoms started this last time, I knew I was going to have issues---just didn't know when.

Today's my B-day and I'm a grandfather--my Chocolate Lab has 3 Chocolate Lab puppies already and more on the way and my Yellow Lab is a week away--maybe 16 pups total for Tina and Tigger. Woody is the Dad. Things can't be all bad :thumbsup:thumbsup:thumbsup
 

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What about a fuller rt6609 which is the 9 speed roadranger? Is it possible to put that puppy in?
 

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What about a fuller rt6609 which is the 9 speed roadranger? Is it possible to put that puppy in?
Anything's possible, how much patience do you have??? Where abouts in Ms. are you located?
 

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Discussion Starter #37 (Edited)
CAD DWG of Fuller T-Case Adapter

:hyper::hyper:Still trying to get info on that Fuller T-Case Adapter used on the Excursion. In the mean time, I bought the shfit lever complete on Ebay for $20.00 plus $11.00 shipping---saved $110.00 compared to dealer cost.

I was playing around today and drafted a CAD file for a T-Case adapter just in case I don't locate that F----d part. The drawing is posted in my photo gallery. I had to convert through 3 programs to make a CAD DWG file into a JEG.

Pretty straight forward on the adapter fab. Ideal thing to do would be to machine the rear bearing cup and race into the adapter like they do on Jeep T-Case adapters. Since the bolts and mounting surface on the rear bearing retainer is large with 1/2" bolts, I plan to surface mount the adapter to the bearing retainer. Need to machine the surface to square it up from the casting imperfections.

Since my rear output shaft is already broken, I can use an off the shelf slip yoke, machine the ID to fit the un-splined portion of the output shaft, then a little MIG welding will do just fine after a press fit.

Any thoughts out there on this plan ???:S:
 

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I thought about trying to put a smaller Fuller 10 in, but figured I'd run into the same Tcase problems, and also possibly a problem clearing the trans with the front driveshaft. I've got an RT9509 in my IH 2275, it's w i d e. Last summer I found NV5600 remans for $2700plus tax and core.:thud: Better than $3400, but how long will they last is my question.

If I was to try a weird swap, I'd try for a 7 speed, but, as you say, you've got to look into gearing. I've got the 3.54s, I wouldn't mind an even hight top gear, as long as it didn't make first/reverse to high.

I'll have to take a look at your adapteer drawing.


Dave
 

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Guys.. I really think I have this Dodge transmission figured out. I blew my nv4500 5th gear once and then again under warranty.. Since then I have decided that the over drive gear in these trucks is NOT what you should be pulling with.. the only strong gear in the NV 4500 or 5600 for that matter is the 1 to 1 ratio gear (4th in the 4500 and 5the 5600). Its direct drive.. so you aren't rattling the gears.. My fuel mileage is actually a little better and the truck runs much stronger up hills now. Granted I do not have a 4.10 rear end... so I am not sure if that messes things up for you guys or not..

When I brought my trans to the 2nd Aamco repair shop they guy said "you aren't pulling anything in 5th are you?".. Boy did I feel stupid.

He cleaned up the mess, replaced 5th again.. we put it in 4th and havent looked back..

Okay, its only been 10k or so... but it makes perfect sense when you look at how the trans is layed out. Take a look at how the over drive gear is connected to the motor.. it goes thru an intermediate gear.. not good in this case.. in the case of the NV4500.. look at the specs.. its designed for 23,000lbs roughly.. I know all you guys are pulling more than that.. you cant BS a BS'er :)


If my trans fails running in 4th I'll repost.. I'll also be out of business.. I have decided it.. if it goes I am shutting it down. And I MAY install a medium duty trans.. but I WON'T ever run a NV 4500 or 5600 again.. $3k to rebuild.. screw that. OUCH that hurt man.

Good luck to all.. I hope you consider my advice.

Also, can we talk about brokers? I have a few I'd like to string up. :)
 

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Here is a history of my transmission failures. First five speed: lost synchro in fourth geat at 24k. Dealer didn't have time to look at it, told me to run it till it popped and they'd put a new one in, which they did. Second five speed: major abuse, overloading, aggressive drag racing, broke a tooth off of third gear. Could have replaced the gear, but I got pissed and tortured on a steep hill towing 12k. Blew it up good, locked it right up. Click for photo Converted to NV5600, lasted about 10k, lost synchros. Warrenteed by dealer. Second six speed: dealer didn't replace one dowel ring, transmission misaligned. Blew up my McLoed twin-disc ($1100 rebuild) and screwed up the transmission. Was forced to run it to failure. Have not been able to afford to fix it.

I don't see where towing in over drive would have caused any of these failures.


Dave
 
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