I followed instructions on removing the engine from the frame and found that the manual fails utterly to take into account that the cab is on the truck and has not half an inch of clearance. For that reason, I am fairly sure that whoever wrote the manual assumed that the assembly-line steps for installing the motor in the factory could be reversed. Undoubtedly the motor, clutch, and transmission were dropped onto the chassis already bolted together, so that the manual author simply printed the steps in reverse order.
What the manual author neglected was that the motor-clutch-transmission sits astride an integral chassis frame cross-member, and the cab sits atop that. That means the motor cannot be removed in the way the manual suggests, because there is no clearance between the top of the clutch-transmission and the bottom of the cab’s foot panel, not nearly enough to lift the clutch-transmission two inches to clear the frame’s cross-member, which is riveted in place. The transmission has to come off first.
I got the Helpful Neighbor to come look at things and confirm my suspicion. He did, and later the same afternoon brought over his transmission jack. Saved me another couple hundred dollars in the process. The transmission is strapped onto the carriage to keep it from rolling off onto the hapless mechanic—which could deliver a two-hundred pound, possibly fatal steel headache, for sure.
The clutch cover, from the driver’s side; oil pan to the left. The immovable frame cross member is on the right.
To get the transmission off required figuring out where the bolts were. There are two bolts holding together the transmission and the clutch housing. They came off without a hitch, but nothing moved. Something else was holding things together from the other side, which meant inside the clutch housing. The clutch cover was simple to remove–bolt on either side into the clutch housing. The back side of the cover slides over the top of the frame cross member to close off the clutch.
Inside the clutch housing, there were a couple of bolt heads hidden inside and threaded into the transmission from the opposite direction. A combination wrench took care of those, since there is not nearly enough room for a socket wrench (but then, the Green Truck was designed before socket wrenches). With those removed, it was a simple matter to push the transmission straight back.
So, the transmission is parked for the time being back by the differential. I can’t get it out from under the truck at this point, and don’t have anywhere else to store, it anyway.
So now let’s get the engine out.
The Green Truck 