[hfjeff]

Major Bummer! As my 3 year old restoration project is winding down (or so I thought) I finally got to drive my 78 CJ7. 3 days ago it had a few clunking noises coming from the tranny area. Today the clunking noises were gone, but now it is just more noisy when driving it. I got the tranny 3 years ago and the shifter pins were missing. Being too new to the CJ world, I assumed they had fallen OUT and not IN. I drained the oil and put in fresh. Now 3 years later and after my first weekend drive, I drained the oil again and it came out GRAYISH SILVER!! With small pieces of metal.

I attempted to take off the top cover, but it only lifts about 2 inches the stops. Why isn't the cover lifting right off? It seems the shift forks are not allowing me to lift it off. The gear teeth look OK from what I could see looking in sideways under the cover.

Is there anything I could use to flush out the tranny and then try fresh oil? I am sure the damage is done, but would really like to make it through the summer before I take it apart this fall for a rebuild. Would brake cleaner be harmful? I would like to rinse out any remaining metal shavings. Any tricks of the trade or am I wasting my time trying to limp along??

[BESRK]

Hard to say without inspecting the tranny.. If you're bent on trying to limp thru the rest of the summer, pull the tranny, hose it out with brake cleaner and fill it with new oil and maybe a quart of Lucas.. see if that'll tide you over. Only down side is, if there is damaged bearings or gears, they may take other parts with them as you continue to drive.. it's your gamble.

[hfjeff]

OK, if I'm going to take this thing back out, it's going to be replaced or rebuilt. The rebuild kit ranges from $50-$100. How difficult is the rebuild and how long does it take? I have a factory service manual, but it is a reprint and does not have the greatest pictures. Also, there may be a part that is faulty and if I don't recognize it and put it back in, I may have continued problems down the road.

Then there would be the bench rebuild from a local shop. I will get prices tomorrow.

Lastly, I could get a rebuild with core exchange, which would be the easiest, but also more expensive. Does anyone know of a good quality, reasonbly priced rebuilt T-150 from a national company?? Advance Auto, Napa, Auto Zone, or something similar?

After 3 years of taking up garage space, I am anxious to get her out on the roads and trails without tranny problems. Thanks.

[BESRK]

Now would be a good time for an upgrade.. maybe a T18 or NP435.. it wouldn't be cheap (the adapter costs about $500) but I think you get to keep your stock driveshafts and it would give you a granny gear and a bullet proof setup.. how bout picking up a used T150 from someone?.. I see used T150s for less than $100.

[hfjeff]

I have thought of the upgrade to a T-18. I have even wandered local salvage yards and found 1 in an F150 for $100. I acquired a Dana 300 a while back and it is in the basement on the bench. But the $500 adapter cost is hard to take right now, especially when I just had my rear driveshaft lengthened 3 weeks ago (4" lift) and that cost $160. Plus the Dana 300 needs a rebuild and the salvage yard T-18 could probably use a rebuild as well.

As far as used T-150's, they are not as common around the upper midwest. Most salvage yard CJ's are picked over.

I am going to just stick with the 3-Speed for now and maybe a few years down the road upgrade. I also have an amc 304 and 360 V-8 sitting on pallets. The 304 is seized up but the 360 turns over so I may do them all at once.

[royleeair]

i just rebuilt my t-177, new 1-2 synco assembly, new 3-4 syncro assembyl and all new small parts, bearings and gaskets. did it in about 7 hours with a chiltons manual. all the parts plus shipping cast me $250 from 4wd and ebay.
take your time and pay attention how it comes apart. not sure about the t150, but a good bearing seperator comes inhandy.
i had never been inside a tranny and was a bit intimidated, but all in all its pretty simple. i haven't had any problems since.
roy

[hfjeff]

Thanks for the advice. I will check rebuild and exchange prices tomorrow. If they are too high I will attempt it myself. If I order the kit monday, should be here for a Saturday rebuild. Want it back on the road by the 18th. How did you know your syncro assemblies were bad? What are the signs? Just excessive wear?

[royleeair]

i was having problem shifting into 3rd and 4th, then finally couldn't get it into either of those gears. when i pulled my shifter cover i could visually see that the syncro assembly was shot. i ordered that assembly and they sent me the wrong one so i figured i'd just replace both. i had already started buying the parts and when all was said and done i can actually rebuild it again with all my extra parts. but in addition to that i found that my needle bearings for the input shaft were non existant. i believe thats what started all my problems.
i'm willing to bet that your fluid is grayish in color becuase your needle bearings are on the way out. i recommend rebuilding it now before it does some serious damage. i'm fairly sure you can rebuild for less than i did.
roy

[meich75]

If you're coming to North Carolina anytime soon I have a T-150 you can have cheap.

[hfjeff]

Just an FYI for anyone who might have been wondering why the oil was gray. Took the tranny and t-case down to a highly respected local shop. Evidently there are some plastic/nylon washers in the tranny that had broken and been ground up. No Damage to any internals. Outstanding! Since I went through all the trouble to rip it out and he only wanted $150 for a bench rebuild (plus the kit of course) I am having the tranny and t-case rebuilt. They will be done on Tues and I should be ready for mud on Friday!! Thanks all for the advice.

[BESRK]

Good deal.. glad to hear it wasn't more serious