3 speed to Auto conversion problem

[GloNDark2]

*** Bare with my, I've got an awesome cold and I'm all high on cold medicine haha

So I got all my parts together, and test fit the dana 20 that came off the original 3 speed to my C4. My problem is, I have the tranny, with the adapter housing, and am using the dana 20 with the original (speed) coupler from the tranny to the t-case input. When I press em together, I have a good 1/2 to 1/4 of an inch of a gap. And I believe it's because the coupler isn't seating all the way.

Is this the way it's supposed to go? Or is there a different coupler that I didn't get with my transmission? Can I cut 1/2" to 5/8" off the coupler on the transmission side?

[highlander]

*** Bare with my, I've got an awesome cold and I'm all high on cold medicine haha

So I got all my parts together, and test fit the dana 20 that came off the original 3 speed to my C4. My problem is, I have the tranny, with the adapter housing, and am using the dana 20 with the original (speed) coupler from the tranny to the t-case input. When I press em together, I have a good 1/2 to 1/4 of an inch of a gap. And I believe it's because the coupler isn't seating all the way.

Is this the way it's supposed to go? Or is there a different coupler that I didn't get with my transmission? Can I cut 1/2" to 5/8" off the coupler on the transmission side?

The C4 spudshaft is shorter than the 3-speed spudshaft. I have heard that you can cut 3/8" off the 3-speed spud shaft and it will work, but have never done it or seen first hand that it works. Make sure the bearing retainer in the intermediate housing has a o-ring on it.

[GloNDark2]

The C4 spudshaft is shorter than the 3-speed spudshaft. I have heard that you can cut 3/8" off the 3-speed spud shaft and it will work, but have never done it or seen first hand that it works. Make sure the bearing retainer in the intermediate housing has a o-ring on it.

Meaning the bearing retainer already inside the adapter correct?

I figure what I have got to lose, I'm gonna cut the sucker off and try it out.

[highlander]

Meaning the bearing retainer already inside the adapter correct?

I figure what I have got to lose, I'm gonna cut the sucker off and try it out.

On the 3-speed adapter it is built in, on the C4 adapter the retainer is a separate piece. The retainer usually stays on the spud shaft (held on with a snap ring) when you take it apart and typically stays in the transfer-case unlike a the 3-speed. That is why I was making sure you have it. Here is a basic tech article for the swap:
http://www.bronco.com/cms/node/61
If you snap a picture of what you have I could explain it better. The 3-speed spud shafts are only like $20 so cut away, the c4 spud shafts are about $60. Are you using a used C4 intermediate housing or a new adapter?

[GloNDark2]

On the 3-speed adapter it is built in, on the C4 adapter the retainer is a separate piece. The retainer usually stays on the spud shaft (held on with a snap ring) when you take it apart and typically stays in the transfer-case unlike a the 3-speed. That is why I was making sure you have it. Here is a basic tech article for the swap:
http://www.bronco.com/cms/node/61
If you snap a picture of what you have I could explain it better. The 3-speed spud shafts are only like $20 so cut away, the c4 spud shafts are about $60. Are you using a used C4 intermediate housing or a new adapter?

I think I found part of my problem (besides the cold medicine and wrenching) I don't have the bearing retainer on the C4 intermediate housing. It's a stock ford piece, but the bearing retainer is gone, so i'm screwed as far as that is concerned. I'll snap a pick tonight when I get home and post it.

[highlander]

You can get the C4 bearing retainer here: http://broncograveyard.com/bronco/c-17
I would also get the bearing retainer seal and o-ring.
If you want it sooner you may try calling WH and see if they have them, there site doesn't list them but you never know what they have laying around. Or maybe even Dusty at WCB.

[GloNDark2]

You can get the C4 bearing retainer here: http://broncograveyard.com/bronco/c-17
I would also get the bearing retainer seal and o-ring.
If you want it sooner you may try calling WH and see if they have them, there site doesn't list them but you never know what they have laying around. Or maybe even Dusty at WCB.

You're the man, thanks for you help. And for the leads on the parts. I've never been a Ford parts guy, Every wheeler/crawler i've built so far has been Chevy drivetrain, so i've got a long road ahead of me.