Transmission Experts... Ever seen this happen?? (Carnage Pics)

[->PrOjEcTGS<-]

Check this out!! I recently rebuilt my transmission myself about 2500 miles ago. First gear was always a bear to get into but I always could get it in. About 1000 miles after the build I ended up with a whine in 1st gear. I assumed the intermediate shaft didn't get shimmed properly because I reused the old shims. So I was planning to take the trans back out and reshim the whole thing. I was waiting for an opportune time to take it out when all of the sudden 2nd gear starts grinding... WTF I now had lots of movement when I put power to 1st gear and 2nd would grind on upshift and downshift. Hmmmm... So I parked it, pulled the trans and swapped in a trans from a buddy. Thanks Whophlungpoo!!!

I finally got time to tear it apart today. The step that holds the intermediate shaft bearing race in is totally gone. WTF And 2nd gear is toast. The synchro looks like it's been in there for 200,000 miles and the hub is worn as well as the intermediate shaft. Is there something I did when I built it to make these parts wear out so fast? Every gear except for 1st shifted GREAT!! I think I'm going to get new parts for 2nd gear as well as find an intermediate shaft and throw it all in my other case. $300 worth of parts...

And here's the pictures!!!

Discuss...

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[dsmmatt28]

You must have set your preloads and endplay incorrect.

 

[donniekak]

Take some better pictures of the 5th gear from the intermediate shaft.

 

[quayzar590awd]

You must have set your preloads and endplay incorrect.

that was my guess as well.

 

[->PrOjEcTGS<-]

Here's the intermediate 5th gear and the outer 2nd gear synchro ring. I don't see any damage on the 5th gear.

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[JackM]

Your clutch looks to have been dragging so terribly that it completely burned up the blocker rings. When you have to force a trans into gear you are ruining expensive parts fast. A trans should never be forced into a gear. If it's blocking you out, it's trying to tell you something.

The oil galley holes which feed the thrust are plugged up and no oil was able to reach the hub and gear thrust contact area. The result was a hub that got worn out in short time as well.

Proper cleaning and alignment of parts when assembling is probably the most important things that needs to be done on a rebuild. Looks like you didn't do that so the parts were destroyed.

I see no evidence of a bearing preload issue.

Jack

 

[->PrOjEcTGS<-]

So, if 1st gear was the gear I was having problems with, why was it 2nd gear that got tore up? 2nd shifted GREAT! And where is my step that the bearing race sits against? The clutch does not drag. I can rev to 7500 rpm without creeping forward. And the clutch pivot ball is shimmed properly.

I agree that I had an oiling issue, But I did clean everything very well before putting it all together. I had to!! You might remember my incident with the termites? http://www.dsmtuners.com/forums/han...pen-you-during-your-transmission-rebuild.html

I think the oiling holes got plugged due to the bearing race step being eaten away at. Metal got into the galleys and plugged them up, which in turn F'd up the gear and hub. But why did the bearing race step get all FUBAR'd?

Also, If my clutch was dragging, Why would the trans that came out of the car after 18,000 miles with this clutch have almost no wear on the synchros? I swapped everything over from the old trans, pivot ball & shims, TOB, and clutch fork.

I don't get it... I guess.

Jack, can I shim each shaft separately? As in, put the input shaft in and put the case together and measure with solder with only that one shaft in? Then, pull out the input shaft and do the same for the intermediate shaft? Is that likely to get better results? Or, should I put the whole thing together and only put solder under one shaft race at a time?