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Old 02-06-2017, 07:25 PM   #21
SBJ
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Awesome. I'll go pick some up this afternoon. It wasn't too bad, just have to bundle up. The hardest part is getting under there in the first place. Once I got under there it was pretty sheltered from the elements.
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Old 02-07-2017, 02:39 AM   #22
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Alright, well I spent about 7 hours today tearing it down. Now I get to spend the rest of the evening just posting and editing all the photos I took. I hope to make this into a write-up at some point. I got the case apart and got all of the shift forks and rods removed. Here's how it looks now:



Here's a shot of the second gear synchronizer. As I suspected, it shows considerably more wear than the others. The gears themselves look okay.



I did notice a few of the teeth are chipped on the reverse idler gear. No doubt the result of putting it in reverse before it was completely stopped. Reverse was working fine before I took the trans apart, so I'm just going to roll with it.



I called it a day after spending a couple hours trying to remove the input shaft bearing. Neither my 3-jaw puller nor the bearing separator could get in behind it. I'm almost thinking it would be easier to separate the two shafts and do it on the press. Then I think the bearing separator could get it. Also, the mainshaft locknut is staked in there good; I broke two screwdrivers trying to get it unstuck (I didn't have a chisel that would fit under there). I believe it's also reverse thread.

Last edited by SBJ; 02-07-2017 at 04:39 AM.
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Old 02-08-2017, 02:45 AM   #23
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More progress has been made. I got it down to the adapter plate. Now to clean everything up and start putting it back together.



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Old 02-08-2017, 11:30 AM   #24
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Let me look around this morning, think i saved the reverse idler out of my parts trans.
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Old 02-08-2017, 11:50 AM   #25
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nevermind......one i have looks worse
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Old 02-08-2017, 03:40 PM   #26
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Thanks John. Now I gotta clean everything up and start putting it back together, but I probably won't get around to that until the weekend. You were right, I didn't need a press to take it apart. Looks like I might need it to put it back together, though. Rookie mistakes were made. I missed with the hammer and buggered up the first couple threads on the countershaft by mistake. I'm thinking I'll sand them smooth and go from there. Lol, after I got the 5th gear synchronizer hub off and pulled the mainshaft it just kind of fell out. Silly me. Also, I bent the washer that goes in front of the input shaft bearing. I hammered it flat and hope it'll work. Once it is back together I will measure the end play at each of the gears and make sure it's within spec.

Still have to go pick up a cleaning solvent, would mineral spirits work? I must say, this job is testing the upper limits of my mechanical abilities. Hope I don't screw it up putting it back together.
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Old 02-08-2017, 11:23 PM   #27
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I have been studying the exploded diagram for the gears. On the diagram it shows a snap ring called an expanded spring on either side of the 3-4 synchronizer hub, mine has no such thing but there are 3 spring loaded keyway things. Forgot to mention... I think I might have misplaced the washer that goes behind the snap ring for the input shaft bearing.
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Old 02-09-2017, 01:39 AM   #28
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Well, I might have just gotten really lucky. I think I found the washer. It is pretty much the same diameter as the input shaft.





Its diameter also fits the mainshaft and I was thinking it was to act as a spacer between the 2nd and 3rd gear clusters. However, I think the machined flange on the mainshaft is for that. Keeping my fingers crossed. Also, needle bearings looked fine.



Is that correct? Sorry to be bombarding you with questions, John. I'll have to buy you a case of beer or something for your troubles.
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Old 02-09-2017, 05:46 PM   #29
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I lied. That washer is for the 3-4 synchronizer hub, behind the snap ring. I'll post a picture of it later. I'm going to check the floor by where I was working once again. Hopefully it just rolled under something.
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Old 02-09-2017, 09:09 PM   #30
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i can go look in the box of parts i have if you do not find it......but its a all apart,maybe i need to bring ya the box to go thru. if there is machined grooves across both face's it must have a thrust washer there.
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