I took next to no pictures at this point, we were paying too much attention to what we were doing to remember the camera action. The fsm has excellent illustrations to rely on though.
- At this point you can remove the reverse idler gear and either rebuild it or set aside for later. Follow fsm procedures here, they are very clear.
- Next remove the counter shaft from the fixture.
Inspect the ends for excessive wear on the bearing surfaces. Inspect the gear teeth for sharp edges, burrs, chips, or discoloration. The counter shaft is a one piece unit, if you find any damage replace it. They can be had on ebay, used, for less than 100$ most weeks.
Now we work the main shaft over. Lol.
BE VERY CAREFUL HANDLING THE SYNCHRO HUBS! They have three dogs with springs and small ball bearings in them that retain the shift collar in position.(mainly the neutral position)
I did not think of a way to keep them from coming apart while pulling them, so just wrap the whole thing in a rag and work on a clean surface so you can find the balls and springs when they go flying. Pull them apart as you get to them before setting up for the next pull on the shop press so you aren't chasing them too far
Note/take a picture of the orientation so that you put it back in with the channels spinning the right way.
Follow fsm procedure for removing the gears and hubs from here on, it's clear and straight forward. You need a bearing separator/puller capable of opening to 9", DO NOT USE A 3 JAW PULLER ON ANYTHING HERE!
- Note orientation of synchro rings, hubs, and gears as you are pulling them.
- Now inspect your main shaft, gears, synchro ramps thst are pressed onto the gears, synchro hubs, and the shift collars for wear, mechanical damage and heat damage.
If any of the ramps on the gears are damaged you'll need to buy them separate, they are considered a "hard" part and are not part of the master rebuild kit.
Springs, ball bearings, and snap rings are also not included in the master rebuild kit, they're in a "small parts kit" easily found on ebay as well.
Inspect the main shaft for wear and damage. Especially on the bearing surfaces
you can see the needle bearing surfaces are a little scuffed, but nothing too crazy. i'd say this shaft is in good shape for over 120k on it.
shift collars are directional and gear cluster specific!
Make a note of their orientation and the orientation of the synchro hubs on the shaft. Fifth/reverse synchro hub is directional
, the others aren't.
CAUTION: One side of the hub has shoulders
around the hub bore, this side of the hub faces the
front of the shaft. One side of the sleeve is tapered
the tapered side faces the front of the shaft.
Gears on the main shaft are in this order.
- The 5/r collar has the ramped portion forward
- The 1/2 collar has a side marked first gear
- The 3/4 collar has the grooved lip forward
- Fourth is on the input shaft
- Third is the front most gear on the main shaft
- Second is next
- Then first
- Then reverse
- Fifth is last after the lip you see on that main shaft picture
- Assemble those shift collar and hub pairings first.
This is the most tedious portion of the rebuild. I wanted to decapitate a puppy during this process. I was swearing like I had tourettes.
Apparently you need fairly large hands to do this job easily, and more patience than I was demonstrating. My friend mike made reasonably short work of them after some trial and error.
There is a special cup to sit the fifth gear synchro hub on while pressing the other hubs onto the main shaft. I highly recommend purchasing it as it has a lip/seat to make sure things don't go slipping on you.
Careful handling those hubs or you may want to shoot people from a clock tower before the day is out.
The only thing the fsm glosses over in assembly is the synchro set up around the 1/2 hub.
There is a center metal ring with four slots called an intermediate ring on both sides. A bronze friction cone with tabs goes around that, then the synchro ring.
Everything else is covered well to the point of putting it back together on the fixture. Really straight forward and the instructions show every step.