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Unread 08-17-2008, 05:24 PM   #1
twomanyjeeps
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Transmission Rebuild - 5th won't budge

Rebuilding an AX-15, I'm to the part where you try to use a two-jaw puller to loosen up the fifth spline gear by placing the jaws behind the fifth counter gear. The darn thing just won't budge, this is a big puller, I've got a large breaker bar on the end and have so much pressure that the rod on the puller is starting to deform, and the gear is still just laughing at me. Has anybody attempted this before have any ideas on how to get this gear off. Any help would be greatly appreciated. And yes the snap ring is off.

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Unread 08-17-2008, 06:00 PM   #2
dave_dj1
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impact gun?
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Unread 08-17-2008, 06:22 PM   #3
laybackman
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Quote:
Originally Posted by twomanyjeeps View Post
Rebuilding an AX-15, I'm to the part where you try to use a two-jaw puller to loosen up the fifth spline gear by placing the jaws behind the fifth counter gear. The darn thing just won't budge, this is a big puller, I've got a large breaker bar on the end and have so much pressure that the rod on the puller is starting to deform, and the gear is still just laughing at me. Has anybody attempted this before have any ideas on how to get this gear off. Any help would be greatly appreciated. And yes the snap ring is off.
Did you remove the snap ring?
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Unread 08-17-2008, 08:42 PM   #4
twomanyjeeps
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Yes, I removed the snap ring...I thought about using the impact gun, but like I said after using the breaker bar, I had so much force on the puller that the very tip of the rod on the puller was starting to deform. I'm afraid to put to much more force on it for fear of flying parts. I'm also not sure how gentle I should be with this. Or just get a bigger puller, but the one I have is just as big as what is portrayed in the manual.
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Unread 08-17-2008, 09:14 PM   #5
lah2420
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I got a puller set from Harbor Freight that has multiple sized bolts and thread counts. I bolted it into the two threaded holes in that pressed-on gear. Then I used an impact wrench on that. The part the wrench is working on pushes directly into the end of the shaft while pulling on the bolts. To me it kind of looks like a steering wheel puller. It seemed to work much easier than the one like you have. If I remember right, I might have had to use a breaker bar to loosen it the first time.

Here it is: http://www.harborfreight.com/cpi/cta...emnumber=37824
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Unread 08-17-2008, 09:57 PM   #6
twomanyjeeps
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Good deal, I'll try that as soon as I can...If I can pry even further, how did the rest of the rebuild go for you?
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Unread 08-18-2008, 08:18 AM   #7
laybackman
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Quote:
Originally Posted by twomanyjeeps View Post
Rebuilding an AX-15, I'm to the part where you try to use a two-jaw puller to loosen up the fifth spline gear by placing the jaws behind the fifth counter gear. The darn thing just won't budge, this is a big puller, I've got a large breaker bar on the end and have so much pressure that the rod on the puller is starting to deform, and the gear is still just laughing at me. Has anybody attempted this before have any ideas on how to get this gear off. Any help would be greatly appreciated. And yes the snap ring is off.
Here's what my FSM says to do for a '95 AX-15 tranny. Grab these pics ASAP:
http://home.comcast.net/~laybackman/...ar_removal.htm
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Unread 08-18-2008, 08:31 AM   #8
twomanyjeeps
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That is the same manual I'm using, the method in figure 31 isn't working, I like the other idea as there is two threaded holes on the spline gear. This way the force is applied directly to the gear instead of using the puller to move the whole assembly.
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Unread 08-18-2008, 08:36 AM   #9
laybackman
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Quote:
Originally Posted by twomanyjeeps View Post
That is the same manual I'm using, the method in figure 31 isn't working, I like the other idea as there is two threaded holes on the spline gear. This way the force is applied directly to the gear instead of using the puller to move the whole assembly.
Do you mean FIG 32?? In any event, try tightening up the gear puller as much as possible then hitting the gear puller on the part where the socket goes with a BFH. Protect the end from mushrooming over with a socket and piece of board. The impact may pop it off.
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Unread 08-18-2008, 08:45 AM   #10
laybackman
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There is a two piece bearing assembly used on the 5th gear. I wonder if it is frozen onto the shaft from wear/friction and the inside of the 5th gear? Unless you 'welded' the 2 piece bearing onto the shaft/gear, using the BFH to pop it loose should work.
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Unread 08-18-2008, 05:05 PM   #11
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Yea when I rebuilt mine. I just threaded two bolts into the holes and used a harmonic balancer puller. Came right off. Dont know why yours is so tight.
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Unread 08-18-2008, 06:41 PM   #12
lah2420
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Quote:
Originally Posted by twomanyjeeps View Post
Good deal, I'll try that as soon as I can...If I can pry even further, how did the rest of the rebuild go for you?
My main problem was getting the bearing off so I could remove 1st gear. You do have to use 1st to pull that bearing. It also put a 25 ton press to the limits to remove and reinstall the bearing. Down side was that I broke some teeth on first doing it. I had a mechanic say to use a couple of pieces of flat aluminum plate to go between the gear and whatever you use to press the gear off. I didn't.
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Unread 08-18-2008, 08:36 PM   #13
twomanyjeeps
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Nothing has worked...Not the harmonic balance, not the tough love with the impact wrench and the hammer. I'm just going to take the guts to the shop and see if they can loosen up the 5th gear and the bearing infront of 1st.
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Unread 08-19-2008, 09:55 AM   #14
twomanyjeeps
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Went to an automotive machine shop this morning and they were able to get it off using the harmonic balance puller type (the one I had from harbour frieght just wasn't cutting the mustard) but the gear fought every bit of the way. Looking at it now, there is several thousands of an interference fit between the shaft and the gear. I'm not sure which one is out of tolerance.
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Unread 10-15-2013, 10:04 AM   #15
waif69
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I had the same problem this weekend, we actually broke the gear puller. After that we took it to the dealership and they got it pulled on Monday. Now to get to the rest of it. I don't want to take a day off work though.
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