64 cj5 poping out of gear - JeepForum.com
 
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post #1 of 6 Old 08-05-2012, 11:22 PM Thread Starter
ridge28
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64 cj5 poping out of gear

My 64 cj5 with the flathead four cylinder and stock three speed keeps popping out of 2 gear and only second gear, any ideas on whats wrong, is it an adjustment issue or something else?

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post #2 of 6 Old 08-06-2012, 05:15 AM
jeepdaddy2000
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No adjustment on the stock T90. You have a broken detent spring, worn fork, worn sliding clutch/syncro keys, bad input bearing, bad pocket bearing, or bad output bearing.
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post #3 of 6 Old 08-06-2012, 08:43 AM
Rick7
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The T90 does have a common issue with popping out of second gear. It is related to forward and aft movement of the main output shaft. It can be fixed in the vehicle without removing the transmission. At one time, there was a shim kit available specifically for this problem. It contained various thickness shims which were horse shoe shaped. You would pick the thickness of the shim which eliminated most of the shaft movment, slip it into position, and then bend i the ends together to keep it in place. I have not seen this kit being sold for some time now but you can make your own by using tin or sheet metal of a thickness that works and cutting it to the correct size.

1) Remove the plate off the back of the transfere case to expose the large gear which is bolted to the transmission output shaft.
2) remove the bolt attaching the gear to the shaft ( you don't need to remove the gear, just loosen it somewhat so it does not restrict shaft movement.
3)remove the floor plate and then the shift tower from the top of the transmission
4) Push the output shaft ( the one attached to the transfer case gear) forward and look at the movement between the back end of the output shaft and the rear of the transmission case. (it doesnt take much movement or looseess here to cause second gear popping out problems)
5) Locate a piece of metal which fill this space and mostly eliminates the fore/aft movement. Cut it in a horshoe shape and slip it between the back of the output shaft and the transmission case. bend the horshoe tabs together to keep it in place.
6) reinstall the transfere case gear, nut, cover as well as the transmission tower and floor plate.
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post #4 of 6 Old 08-06-2012, 07:27 PM
jeepdaddy2000
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Interesting. I am fairly familiar with the T90 and never heard of a shim kit.
Are you saying the shim goes between the inner shoulder of the mainshaft and the inner bearing race on the rear bearing?
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post #5 of 6 Old 08-08-2012, 09:43 AM
Rick7
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Yes- just forward and against the rear bearing race. The kit was available during the late sixtys/ early seventies. I dont recall who supplied it at that time. It contained 5 or 6 different thickness shims and was very effective in stopping second gear pop-out. I used on 4 or 5 different T90's with 100% effective results.
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post #6 of 6 Old 08-08-2012, 05:07 PM
jeepdaddy2000
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Quote:
Originally Posted by Rick7 View Post
Yes- just forward and against the rear bearing race. The kit was available during the late sixtys/ early seventies. I dont recall who supplied it at that time. It contained 5 or 6 different thickness shims and was very effective in stopping second gear pop-out. I used on 4 or 5 different T90's with 100% effective results.

Good info....
Well, I learn something new every day.
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