Rebuilding AWD Trans

[DSMLoverFromUA]

Good work, i have rebuilded my awd trans also but for a 2g and about6 months later the big nut that holds the 5th gear came loose, its like 36mm and you have to dent it in, well make sure its dented in good and it is tight the way it suppoused to be. Looks like from the pictures that you have and the same parts busted as i did. I also had the a gear cheapet but it was 2nd and2 of my forks were worn out to nothing. Good Luck.

 

[andrewjscott]

trans is all together. The gear clusters spin without binding. Seems to shift gears too. Is there any good way of testing a trans without putting it into the car. If there is something wrong i don't want to have to pull it out again.

 

[pneumo]

trans is all together. The gear clusters spin without binding. Seems to shift gears too. Is there any good way of testing a trans without putting it into the car. If there is something wrong i don't want to have to pull it out again.

You kinda already tested it. I like to spin the input shaft while shifting into each gear. Check that the shaft spins smoothly in each gear, and that you can shift into each gear. Some gears are harder to turn, so I like to slide a clutch disc onto the input shaft so I have something to grab onto.

 

[andrewjscott]

cool, i actually have a tool that a friend made up that will work perfectly. its an old clutch spline welded to a piece of flat stock. i used it to hold the input shaft to torque the 32mm nuts but i guess it'll work for spinnin the trans too. thanks.

 

[JackM]

If you are in need of parts, I ship anywhere in the world. Everything from parts to whole trannies. What some have been doing is shipping us the gear clusters and center diffs to rebuild. That way they get our cool double synchros, 4-spider upgrades, and machining and they know its done right. All they have to do is pop it back in the case and make sure the preloads are correct. Shipping gear clusters is a lot cheaper than shipping the whole trans.

Jack
www.jackstransmissions.com

 

[andrewjscott]

Trans is together, gave it a spin in all gears, and it seems to shift great. It's now mounted to the engine ready to drop into the car. I'll let everybody know if it works as well under driving conditions as it seems to on the bench.

 

[andrewjscott]

trans is in the car, goes into 1st, 2nd, 3rd and 4th easily. but 5th and reverse cannot be engaged from inside the car. If i pop the hood and pull up on the shifter lever, i can get it into 5th and reverse. I assume that an adjustment on the shifter base should suffice. Also the shifter lever assembly itself seems to be worn. I have the metel underhood bushings as well as the shifter base but there is still a lot of slop.

Can somebody explain to me the proper procedure for adjusting the shifter cables. The shifter seemed centered and the when i read through the VFAQ it only really shows how to center it. I only have the 5th/Reverse problem.

 

[absolute_DSM]

Ive been watching this thread for a while and its a very good thread. But I can tell you now, the shifter assembly is not adjustable.

 

[andrewjscott]

Ive been watching this thread for a while and its a very good thread. But I can tell you now, the shifter assembly is not adjustable.

On a 2g it may not be adjustable, but i have a 1g. Heres the VFAQ on how to center it, http://www.vfaq.com/mods/shifter3.html. i just need somebody to elaborate a little on how to fix side to side movement when everything seems centered.

 

[andrewjscott]

Drove the car home today. Almost all good except for a few minor things that seem normal, i just wanna make sure. Theres a vibration that starts to come in about 110km/h and gets progressively worse to about 125km/h I did have to remove the driveshaft but i marked everything and put it back the same way it came out. I also pulled the whole rear suspension assembly out (including the diff). any suggestions on what this.

 

[andrewjscott]

forgot to add, i performed the transfer case recall with a new yoke, could that be the cause of this driveline vibration?