Transmission Reassembly Mistake

[TalonJohn94]

When I was reassembling my transmission after a center differential replacement, I impacted the reverse gear in backwards. This action scored the inner case, and getting it out chipped the gear itself slightly. I also put part of the fifth gear assembly in backward. (the side of the spacer with the slit down the middle goes toward the clutch not the other way)

Does anyone think I should look into replacing the center case, or the reverse gear?

 

[pneumo]

It all depends on how bad the damage is. I've run trannies with small chips on the teeth with no problem. The chips were all about 1mm round or less. Anything bigger and I'd think twice.

If the groove in the case is too big, just take it to a good aluminum welder and have the groove filled in. Check it with the gear to make sure the weld bead isn't too thick. File it down if it is.

 

[poorboyj]

I've been there too. That's how you learn right? In my case I just flipped it the right way and reassembled it. Everything was fine. As long as there are no cracks, you should be okay. The surface under the driven 5th is just clearance anyways. the gear seats on the shaft.

Jay

 

[TalonJohn94]

Thanks for the advice. Sadly enough, I made the same mistake on the reverse gear about 2 years ago - except that time I tried to drive it. It wouldn't go until I dropped the clutch. Everything was going fine until I realized the gear went right through the outer case and spilled transmission fluid all the way down the highway.

Luckily I had a donor transmission to cannabilize, and replaced the cases.

I just don't want to screw this one up, because its a full ShepRacing race transmission. Sure John Shepherd might assemble the strongest trannies on the road, but they don't stand a chance in my basement, with me armed with screwdrivers and hammers.

I'll soak the inside with brake cleaner, let it dry and seal it all up.

 

[1fast97gsx]

If the casing is only a little chipped it's not a big deal. As far as the reverse gear it depends on how bad the damage is. Chances are it's ok ... take a look at it and see how badly it's chipped. The 5th gear assembly can just be removed and flipped and it'll be ok. Pay attention to both the punch mark on the hub as well as the orientation of the slider. Chances are you're ok if you just flip things around and reassemble.

 

[TalonJohn94]

Thanks, we'll see. I reassembly and sealed/bolted it up now. I made one last mistake - put the sealant on, started to bolt it up - and realized I had that last synchro (5th) sitting right next to the transmission. SO .. I took the case back apart - threw it on and rebolted it. It had only been like 5 minutes so I think the RTV will hold.

I'm usually not THIS absent minded, but it should all work out.

One last question: After it was all reassembled - I was checking the shifter arm positions. On the arm that actually does the shifting (not the one that pulls the other one up or down) - Is it supposed to be able to turn all the way toward the transmission as well as away. When you push the arm toward the bell housing - it doesn't shift anything but turns that way. I don't think this would be possible with the shifter cables in place, but it just doesn't feel right like something is loose. Does anyone know what I'm talking about?

 

[pneumo]

Do you mean the shift arm doesn't have any resistance? It sounds like you might have left out one of the roll pins that holds the shift fork to the rail. It's easy to check, just remove the three poppet bolts (the three bolts in a row) and remove the small spring and ball. You should see the shift rail inside with notched detents facing you. If all you see is smooth rail, take it apart and start over.

again

yay

 

[TalonJohn94]

But I only took the transmission apart down to the point where you can take the center differential out. The only roll pin I removed was the one for the fifth gear fork - which I know I pounded in. I'll do what you said and check - what position do you have to have the arms in to do it?

I could only set up something with my extra shift cables and shifter assembly (and seat) I have in my basement - like a simulation to see if it shifts right.

 

[pneumo]

Do you mean the shift arm doesn't have any resistance?

Ahem ^ ?

I thought you said you put the reverse gear in backwards? The reverse gear is deeper inside the trans than the center diff. Are you talking about some other gear? Maybe the reverse syncro? Please describe it in more detail.

You don't need to hook up the cables to test the trans. The cables don't have any detents or stops in them. All the stops and detents are built into the trans. Know what I mean?

 

[TalonJohn94]

The gear in between the fifth gear and the Viscous Coupler. Seen when you take off the first case. I don't know what detents are but I am going to look at it a little bit more tomorrow...