I currently have a '78 CJ5 with a T150 popping out of first. I picked up a parts Jeep this weekend that had a T150/D20 with it. It appeared to be in very bad shape, so I figured I would pop the transmission open and have a peek to see if this was something I wanted to tackle or not. When I separated it from T case I could hear a bunch of parts rattling in there. I guess these were needle bearings and such. Anyway, I'm having trouble with the 3rd step of procedure where it says remove locknut, flat washer, and T Case gear. Is there a trick to getting this lock nut off? Thanks for any input.
The loose parts are the syncro blockers and the pocket bearings (they go between the input and main shaft). Loosing these is a common problem with the T150 during disassembly due to the main shaft sliding back when the t case is removed.
To remove the locking nut, place both locking rings in the transmission on a gear (it looks like your there now). That will "lock the trans in two gears, keeping the mainshaft from turning. Using a socket, remove the self locking nut (an air impact will make short work of this), bull gear, and adapting ring. This will allow you access to the rear bearing snap ring. The rest of the disassembly instructions should be in your book.
On a side note, be sure to keep an eye on the rear shaft during reassembly. They have a bad habit of sliding back and if that happens, you will be tearing the trans down again. You can use a piece of wire wrapped around the mainshaft to help retain it. Bolt it to one of the holes, wrap it around the bull gear, and bolt it tight to the other side on the back of the trans as a bearing retainer.
Thanks for all the help especially the pics! !! I've got everything apart and am gonna clean everything up and I will post more pics to get opinions on the condition of parts. This was more of a bucketlist rebuild than anything, but if I succeed I will be very happy. Thanks again for the help so far. David
Yep they are both there. We're all good so far. Been cleaning parts this afternoon. The "innerds" look good overall from what I can tell but the previous owner never said anything was wrong with it. I've got it apart though, so there's no way it's going back together with out at least a minimal rebuild kit. Stay tuned.
side note: Does anyone have a link to an excellent step by step rebuild procedure? The manual is great if you know the terminology and can glance at a bad parts breakdown and know what your looking at.