Clutch service update #3

[Bank of SHO]

I spent a bit of time cleaning out all of the RTV AAMCO applied during the last service. They even used it on the 'wet' bolts instead of teflon tape. I even had to clean it out of the synchros (in the spring tabs).

You will all like to to hear they have found a way to prevent future differential pin failure. At the time, before I owned the car, a new differential was installed though the tranny had not 'grenaded'. They said they had a way of 'pinning' the pins. Well now I know what they meant. They used a center punch to deform the metal on the differential case housing around the differential pins. It's not even a good job. Oh, and the synchro springs weren't even assembled correctly. Those people make me look good, and that's not good.

Refreshing the transmission with new blocking rings seems to have gone well, but there may be a problem. The shift forks came apart during disassembly. Tonight I reassembled according to the vague Helms guide on the forks. The lowest synchro on the main shaft doesn't move. I think there is a problem with the fork assembly. The gear assembly was followed step-by-step with the video. The reason I even checked is because the manual says to position the shift shaft(?) in the center of the gear selector teeth (neutral position). It is in neutral, but between the 1/2 position. It can be moved into gears 1 and 2, but not farther right in neutral. This is with a punch in the end of the shaft. Any thoughts here?

The dog teeth on the gears look almost brand new, a testament to the non-abuse the car has seen. Fifth gear is the only one with wear.

Wednesday is the last day I can work on it as I have company visiting for a long weekend. The tranny is becoming a sore spot for me. I think it would be easy if I saw how it is done in person. Maybe next time...by then I will have forgotten anyway. Sigh...

 

[SHOoff89]

This is exactly why I am scared stupid of my tranny.

Good luck!!

 

[sdpatt]

The shifting of the assembled (but not bolted) transaxle should be possible with a screwdriver through the eye in the shift shaft stub. All gears should be accessible with non-forced motion. Either the shifting mechanism is not assembled correctly or the synchro is not assembled or installed properly. You must be able to access all five forward gears and reverse with the screwdriver method before reassembling the case.

 

[Bank of SHO]

Everything but the main shaft fork was assembled step by step along the video. Great care was taken. I'll play with the forks again, but I wish there was a better diagram than the Helms provides.

Does anyone have a close-up picture of the main shaft forks where the two pieces are coupled?

 

[masho95]

I'm assuming that you are trying to shift everything with the case half off again? With the case half off the shift shaft retaining pin isn't putting pressure on the mainshaft forks. This causes a problem when trying to shift the tranny by hand with the case off. What happens is the main shaft forks move a little bit and the notches where they rotate get misaligned and it will be unable to shift. If you look closely at the forks there is a tab on one part of the fork and a notch that it slides through when the forks turn. The shift shaft retaining pin keeps everything lined up so that the turn freely (and you can push the shifter from side to side in neutral). If you are having problems moving the gear selector side to side you'll probably notice that the tab on part of the fork isn't aligning with the notched part of the other.

 

[Bank of SHO]

Bingo masho95 and Scott! I just figured it out before checking for respnses. Thanks. It's nice to know I have it right.

The first time, the fork shaft linkage to the shift lever was not at a 90 degree angle. This really limited travel. While fiddling with everything, a synchro fell apart as well. So the main shaft was reassembled yet again.

The second time, the shift fork linkage oriented the same way, so I rotated it almost all the way around until it sat at the 90 deg. angle. It then took me a while to realize the shafts needed to be supported on top to make the fork coupler function correctly. I'll go try it with the case half on now.

Thank you very much. I was beginning to think I'd have to take it to a shop.

 

[masho95]

And when you reassemble the case half back on you may need to stick something in the shift shaft retaining pin hole to make sure that the forks are lined up, before you put the bolt back in. After pulling the tranny on my car twice in 2 weeks I think I learned a little bit. My last tranny pull, disassembly, and reinstallation took me 12 hours with breaks. I have another one coming up when all the parts come in and I hope to do it in under 12 hrs. Good luck with the rest of the rebuild.

 

[Bank of SHO]

When I test fitted the case half, the problem recurred. I tried several times, but it won't go back and forth in neutral. It works if I keep my hand on the fork and gear shafts. It seems it should have worked with the case half holding things together. What am I missing?

Thanks for the ongoing help. I won't be around until Monday. I will check this thread when I get back. This is very frustrating.

Edit: Do I need to install that retaining bolt you wrote about even for a test fit? Is that the difference?

<small>[ August 21, 2003, 02:24 AM: Message edited by: Bank of SHO ]</small>

 

[masho95]

Oh yeah. You definitely need to install the shift shaft retaining bolt. It's the lower one to the right of the fill plug. With out having that in the forks are still free to flop around a little bit. Just like in the SHONut Clutch video, where he drains the tranny fluid from, he suggests putting the bolt right back in or else you are going to have tranny issues. Good luck getting everything working, and I'm sure once you're done you are going to be happy with all the work you've done!

 

[Bank of SHO]

Back from the long weekend visit. There are some seriously fun rides here. Anyway, thank you very much. The tranny is back together again and it shifts into all gears.

Yet another problem to follow in a new thread though...TOB pin.

 

[masho95]

It worked fine after you reinstalled the case half and put the shift shaft retaining pin back in?

 

[Bank of SHO]

Yessir, I realigned the fork couplers and test fit the case half with the retaining pins/bolts. It worked that way, so I went ahead with the real installation. I then shifted into every gear a few times. All seems well.

Thank you for talking me through my tough spots. I do realize it's my own ignorance creating these speed bumps, and everyones patience is greatly appreciated. beer beer beer

 

[masho95]

Bank of SHO:
Thank you for talking me through my tough spots. I do realize it's my own ignorance creating these speed bumps, and everyones patience is greatly appreciated. beer beer beer

You are very welcome. I'd hardly call it ignorance...more like inexperience If it wasn't for this forum and the shotimes list I would probably know a TON less than I do about my car. Asking questions is how you learn. Good luck with the rest of the reinstallation.