Transmission teardown/rebuild

[Coyote Patrol]

Update on the transmission. When putting it back together leave the countershaft at the bottom of the case. Grease the pocket of the input shaft, this will hold the needle bearings in. Place the inputshaft with the needle bearings into the case (do not install the large bearing yet). Now install the outputshaft with the syncros and hub (the syncro hub has a raised end and a flat end, the raised end will face the inputshaft. Now you can mate the input with the output, dont slide it on all the way yet, because all the shafts now have to fit together like a puzzle. With the input and output slightly put together you will need to get the countershaft raised and into the bearings, at the same time you will need to line it up with the input and output shafts. Sounds hard, but its not too bad. When all of it fits together right, you can now install the input bearing (use a brass drift on the inner race for this). Next you can install the rear outputshaft bearing (same thing with the brass drift). This is where i was going to install the spacers to get rid of all the play at the syncro hub. I installed 1/8" worth of spacers on the outputshaft before i installed the bearing, it took care of the play, but i didnt like how the gears lined up between the outputshaft and the countershaft so i pulled the spacers back out. Make sure you grease the lip seals when you install them into the tranny or transfer case.

[sleepyzzz]

Great write up and very clear. sounds like you need an extra pair of hands helping hold all that together

[Esteban]

Great write up and very clear. sounds like you need an extra pair of hands helping hold all that together

X2

Excellent job Ron, thanks. Your write up, tips, and photos are making this thread a must read for everyone doing the transmission. It is way better than the Service Manual. Now you'll have to complement it with the Transfer Case write up.

This should become a sticky.

[doc]

Great info thanks!

[Coyote Patrol]

You're welcome i was glad to do it. Do you guys want a new thread on the transfer case, or just start it right here?

[RiverPatrol]

You're welcome i was glad to do it. Do you guys want a new thread on the transfer case, or just start it right here?

Start a new thread. I'll make it a sticky also.

[sleepyzzz]

grease holding the needle bearings up is the way to do it, and that works great when replacing u joints with the needle bearings in the cups. we did it all the time when we repaired or replaced yokes and u joints on drive shafts. just make sure that your hands are clean so you don't get grit down in the grease working in the needle bearings.

[donpats67]

I changed all bearings, gears, countershaft. now My transmission too got the same problem of 1/8 inch play when the main shaft is pushed front. Any solution plz.

[EricB]

Thank you Ron!