[TimG]

I'm doing a trans rebuild right now and have run into a pretty big problem. I know most of you guys have never opened up, let alone rebuilt a transmission but I had the bright idea to do it.

Everything went well. All the parts fit together properly and within clearances. I clearanced the shims with the crush solder method and everything came out consistant and happy. My results were:

1. Front Diff - 1.43mm
2. Front/Center Output Shaft - 1.69mm
3. Center Diff Housing - 1.64mm
4. Intermediate Shaft - 1.22mm
5. Input Shaft - 1.33mm

Each shaft has it's own designated clearances or preloads so I simply added or subtracted the limits to the solder thickness' and came up with these shim sizes.

1. Front Diff - 1.38mm
2. Front/Center Output Shaft - 1.77mm
3. Center Diff Housing - 1.56mm
4. Intermediate Shaft - 1.30mm
5. Input Shaft - 1.33mm

I went to put the transmission together today and upon placing the first two cases together, I ran into a big problem. The tighter I tightened the bolts for the case, the harder the front/center output shaft gets to turn until it totally binds up and locks itself in the case.

Can someone who has experience with this type of thing give me some pointers as to where to look for my answers? I re-clearanced the transmission and came up with near identical results so I'm literally lost.

Update: I just re-shimmed the center/front output shaft and attempted to turn the shaft and it's locked with the crushed solder in there. Obviously the crushed solder is too thick. How can this be? I'm using 3mm plumbing solder, which is recommended for this rebuild.