So made some progress yesterday, and only have a few questions so far. I will put the questions in bold
to make it a little easier to pick them out.
Got the case cleaned up.
After that got the reverse idler gear needle bearings in place and installed the idle gear washers. (washers not pictured)
First question related to the reverse idler thrust washers..
The instructions say "Note that the thrust washers have flats on them. Be sure to install the washers so these flats will face the mainshaft. Also, be sure to engage the thrust washer locating tabs in the case locating slots." So I understand what they want me to do. My old thrust washers were metal and in good shape so I reused them instead of using the plastic one the kit came with. The thrust washers are exactly the same so to install them the way the instruction say one has to have the locating tab facing up and out and the other has to have the locating tab facing down and out. The problem that I ran in to is that when the tab is facing down and out it does not properly fit in to the case locating slot at the bottom of the case.
I tried both my old thrust washers and the new ones, also tried both cases and the locating tab just is to big to fit in the case which you can see in the picture. I looks to me that the flats have to face the main shaft so that the cluster shaft assembly has the proper clearance. I went ahead and installed the reverse idler with the one thrust washer orientated in the wrong direction, but again its the only way that fits properly. If installed the way the instructions say it does not fit flush against the case.
After that I assembled the cluster shaft (not pictured just needle bearings and 2 washers) and then test fit in to the case and everything appears to clear properly. The one idler thrust washer that is the correct way appears to be the only one that really needs the clearance. Anyone else run in to this problem?
So moved on to the main shaft next. Took the old one apart and cleaned it up. Next assembled the 1st / 2nd gear synchro hub. (front and back picture) I made sure that when I installed the synchro springs that I open end faces 180 opposite each other.
After that installed the 1st /2nd gear synchro hub and reverse gear on the main shaft. Installed its snap ring.
From that point installed the first gear synchro.
Then 1st gear and its 1st gear thrust washer. (This looks different from the other thrust washers and amounts to just a washer looking thing.)
From there I 2nd gear synchro.
Then slid 2nd gear on to the shaft.
After second gear went on I installed the tabbed 2nd gear thrust washer and then the 2nd gear snap ring.
Next 3rd gear went on.
And to finish up the night I then slid the 3rd gear synco on the shaft.
So hear comes the next question
The next thing to do is assemble the 3rd / 4th gear syncro hub. The directions say than on this hub there should be alignment marks.
I cleaned the parts off good and can not find anything that looks like the marks.
Also I noticed that the 3rd /4th gear syncro hub parts look different
between my hub parts (the one pictured off the shaft) and the hub parts on the spare tranny I am using as a guide.(The one pictured on the shaft.)
If you look at the two parts you can see mine is flat on the top and square and the spare one is beveled on both ends. I first though that is was wear but then came across a picture on eaglekeepers built and his is beveled as well. Ideas?
My thoughts were to take / use the hub off of the spare shaft and make sure that I keep it aligned.
So that is it for now tomorrow once I get some of these questions answered I am going to finish up. All you tranny experts please look over what I have done so far! Thanks guys!